Localized heating to improve interlayer bonding in 3d printing

ABSTRACT

The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.

CROSS-REFERENCE

The present application is a continuation of International ApplicationNo. PCT/US2017/035551, filed Jun. 1, 2017, which claims the benefit ofU.S. Provisional Patent Application No. 62/344,250, filed Jun. 1, 2016,each of which is entirely incorporated herein by reference.

BACKGROUND

Additive manufacturing has been utilized for printing three-dimensionalparts by depositing successive layers of material in an automatedmanner. Techniques of additive manufacturing include, withoutlimitation, fused deposition modeling (FDM), fused filament fabrication(FFF), Plastic Jet Printing (PJP), extrusion-based techniques, jetting,selective laser sintering, powder/binder jetting, electron-beam melting,and stereolithographic processes. Using these techniques, a material(e.g., a heated and/or pressurized thermoplastic) may pass through aprint head. The print head may be moved in a predefined trajectory(e.g., a tool path) as the material discharges from the print head, suchthat the material is laid down in a particular pattern and shape ofoverlapping layers. The material, after exiting the print head, mayharden into a final form.

SUMMARY

In an aspect, the present disclosure provides a method for printing atleast a portion of a three-dimensional (3D) object, comprising (a)receiving, in computer memory, a model of the 3D object; (b) subsequentto receiving the model of the 3D object, directing at least one filamentmaterial from a source of the at least one filament material towards asubstrate that is configured to support the 3D object, therebydepositing a first layer corresponding to a portion of the 3D objectadjacent to the substrate, which first layer is deposited in accordancewith the model of the 3D object; (c) depositing a second layercorresponding to at least a portion of the 3D object, which second layeris deposited in accordance with the model of the 3D object; and (d)using at least a first energy beam from at least one energy source toselectively melt at least a portion of the first layer and/or the secondlayer, thereby forming at least a portion of the 3D object. In someembodiments, (a)-(c) are performed using fused deposition modeling. Insome embodiments, the method for printing at least a portion of a 3Dobject, further comprises depositing one or more additional layersadjacent to the first layer prior to depositing the second layer. Insome embodiments, (b) comprises (i) directing the at least one filamentmaterial from the source to an opening, and (ii) directing the at leastone filament material from the opening towards the substrate.

In some embodiments, the at least one filament material is a compositematerial. In some embodiments, the at least one filament material is acontinuous fiber composite. In some embodiments, the continuous fibercomposite is selected from the group consisting of glass, carbon,aramid, cotton, silicon carbide, polymer, wool, metal, and anycombination thereof. In some embodiments, the at least one filamentmaterial has a cross sectional shape selected from the group consistingof circle, ellipse, parabola, hyperbola, convex polygon, concavepolygon, cyclic polygon, equilateral polygon, equiangular polygon,regular convex polygon, regular star polygon, tape-like geometry, andany combination thereof. In some embodiments, the at least one filamentmaterial has a diameter of about 0.1 millimeters to 5 millimeters. Insome embodiments, the at least one energy source is a laser and/orsource of a hot fluid.

In some embodiments, the at least one energy source is in opticalcommunication with one or more beam splitters, which one or more beamsplitters splits the energy beam from the at least one energy sourceinto one or more beamlets that yields the at least the first energybeam. In some embodiments, the one or more beam splitters is selectedfrom the group consisting of prism, glass sheet, plastic sheet, mirror,dielectric mirror, metal-coated mirror, partially reflecting mirror,pellicles, micro-optic beam splitters, waveguide beam splitters, beamsplitter cubes, fiber-optic beam splitter, and any combination thereof.In some embodiments, the method for printing at least a portion of a 3Dobject further comprises one or more optical wedges in opticalcommunication with the one or more beam splitters, which one or moreoptical wedges form the at least the first energy beam. In someembodiments, the one or more optical wedges form the at least said firstenergy beam in a uniform orientation. In some embodiments, the one ormore beamlets passes through one or more focusing lenses prior topassing through the one or more optical wedges. In some embodiments, theone or more focusing lenses adjust a ratio of a minor axis to a majoraxis of the one or more beamlets. In some embodiments, the one or morebeamlets have an elliptical polarization. In some embodiments, the oneor more beamlets comprises a minor axis of at least about 1 millimeterand a major axis of at least about 15 millimeters. In some embodiments,the one or more optical wedges directs an optical path of the at leastthe first energy beam of a given location, direction, or angle normal tothe substrate and/or along the substrate among one or more locations,directions, or angles. In some embodiments, the one or more opticalwedges is a Risley prism pair. In some embodiments, the one or moreoptical wedges has a refractive index of at least about 1.

In some embodiments, the one or more optical wedges comprise a firstoptical wedge and a second optical wedge. In some embodiments, the oneor more optical wedges has a diameter from about 0.1 inches to 1 inch.In some embodiments, the first optical wedge rotates relative to thesecond optical wedge to change the direction of the at least the firstenergy beam. In some embodiments, the first optical wedge and the secondoptical wedge are angled in the same direction increase an angle of theat least the first energy beam with respect to a reference. In someembodiments, the first optical wedge and the second optical wedgerotates in an opposite direction to allow the at least the first energybeam to pass vertically through the one or more optical wedges. In someembodiments, altering an angle of incidence of the first optical wedgeand the second optical wedge alters a fluence of the at least the firstenergy beam. In some embodiments, the at least said first energy beam isincident on the at least one filament material and on the substrate. Insome embodiments, the at least said first energy beam covers at least aportion of the at least one filament material. In some embodiments, theat least the first energy beam is directed along a given angle among oneor more angles relative to the dispensing route of the at least onefilament material.

In some embodiments, (b) of the method for printing at least a portionof the 3D object comprises directing at least one filament material to acompaction unit. In some embodiments, the method for printing at least aportion of the 3D object further comprises compacting the at least onefilament material by the compaction unit to form at least one compactedfilament material. In some embodiments, the compaction unit comprises arigid body, one or more idler rollers, at least one freely suspendedroller, a coolant unit, or a combination thereof. In some embodiments,the at least one freely suspended roller has a diameter from about 1millimeter to 10 millimeter. In some embodiments, (b)-(d) of the methodfor printing at least a portion of the 3D object comprises using one ormore sensors to measure one or more temperature(s) along the at leastone filament material. In some embodiments, the one or more sensorscontrol intensities of the at least the first energy beam. In someembodiments, the one or more sensors is an optical pyrometer. In someembodiments, a real time simulation provides feedback control of a givenlocation, direction, or angle of the at least the first energy beamnormal to the substrate and/or along the substrate among one or morelocations, directions, or angles. In some embodiments, the at least thefirst energy beam heats the at least one filament material withoutmelting a deposited portion of the at least one filament material. Insome embodiments, the at least the first energy beam heats and melts adeposited portion of the at least one filament material at a givenlocation among one or more locations. In some embodiments, altering adirection of a major axis of the at least the first energy beam relativeto the substrate or the at least one filament material alters a fluenceof the at least the first energy beam.

In another aspect, the present disclosure provides a method for printingat least a portion of a three-dimensional (3D) object, comprising (a)receiving, in computer memory, a model of the 3D object; (b) subsequentto receiving the model of the 3D object, directing at least one filamentmaterial from a source of the at least one filament material towards asubstrate that is configured to support the 3D object, therebydepositing a first layer corresponding to a portion of the 3D objectadjacent to the substrate, which first layer is deposited in accordancewith the model of the 3D object; (c) using at least a first energy beamfrom at least one energy source to melt at least a portion of the firstlayer; and (d) depositing a second layer corresponding to at least aportion of the 3D object, which second layer is deposited in accordancewith the model of the 3D object, thereby generating the at least theportion of the 3D object. In some embodiments, (a)-(d) are performedusing fused deposition modeling. In some embodiments, the method forprinting at least a portion of a 3D object further comprises repeating(b)-(d) one or more times. In some embodiments, (b) comprises (i)directing the at least one filament material from the source to anopening, and (ii) directing the at least one filament material from theopening towards the substrate.

In some embodiments, the at least one filament material is a compositematerial. In some embodiments, the at least one filament material is acontinuous fiber composite. In some embodiments, the continuous fibercomposite is selected from the group consisting of glass, carbon,aramid, cotton, silicon carbide, polymer, wool, metal, and anycombination thereof. In some embodiments, the at least one filamentmaterial has a cross sectional shape selected from the group consistingof circle, ellipse, parabola, hyperbola, convex polygon, concavepolygon, cyclic polygon, equilateral polygon, equiangular polygon,regular convex polygon, regular star polygon, tape-like geometry, andany combination thereof. In some embodiments, the at least one filamentmaterial has a diameter of about 0.1 millimeters to 5 millimeters. Insome embodiments, the at least one energy source is a laser and/orsource of a hot fluid. In some embodiments, the at least one energysource is in optical communication with one or more beam splitters,which one or more beam splitters splits the energy beam from the atleast one energy source into one or more beamlets that yields the atleast the first energy beam. In some embodiments, the one or more beamsplitters is selected from the group consisting of prism, glass sheet,plastic sheet, mirror, dielectric mirror, metal-coated mirror, partiallyreflecting mirror, pellicles, micro-optic beam splitters, waveguide beamsplitters, beam splitter cubes, fiber-optic beam splitter, and anycombination thereof.

In some embodiments, the method for printing at least a portion of a 3Dobject further comprises one or more optical wedges in opticalcommunication with the one or more beam splitters, which one or moreoptical wedges form the at least the first energy beam. In someembodiments, the one or more optical wedges form the at least the firstenergy beam in a uniform orientation. In some embodiments, the one ormore beamlets passes through one or more focusing lenses prior topassing through the one or more optical wedges. In some embodiments, theone or more focusing lenses adjust a ratio of a minor axis to a majoraxis of the one or more beamlets. In some embodiments, the one or morebeamlets have an elliptical polarization. In some embodiments, the oneor more beamlets comprises a minor axis of at least about 1 millimeterand a major axis of at least about 15 millimeters. In some embodiments,the one or more optical wedges directs an optical path of the at leastthe first energy beam of a given location, direction, or angle normal tothe substrate and/or along the substrate among one or more locations,directions, or angles. In some embodiments, the one or more opticalwedges is a Risley prism pair. In some embodiments, the one or moreoptical wedges has a refractive index of at least about 1.

In some embodiments, the one or more optical wedges comprise a firstoptical wedge and a second optical wedge. In some embodiments, the oneor more optical wedges has a diameter from about 0.1 inches to 1 inch.In some embodiments, the first optical wedge rotates relative to thesecond optical wedge to change the direction of the at least the firstenergy beam. In some embodiments, the first optical wedge and the secondoptical wedge are angled in the same direction to increase an angle ofthe at least said first energy beam with respect to a reference. In someembodiments, the first optical wedge and the second optical wedgerotates in an opposite direction to allow the at least the first energybeam to pass vertically through the one or more optical wedges. In someembodiments, altering an angle of incidence of the first optical wedgeand the second optical wedge alters a fluence of the at least the firstenergy beam. In some embodiments, the at least the first energy beam isincident on the at least one filament material and on the substrate. Insome embodiments, the at least the first energy beam covers at least aportion of the at least one filament material. In some embodiments, theat least the first energy beam is directed along a given angle among oneor more angles relative to the dispensing route of the at least onefilament material.

In some embodiments, (b) of the method for printing at least a portionof a 3D object comprises directing the at least one filament material toa compaction unit. In some embodiments, the method for printing at leasta portion of a 3D object further comprises compacting the at least onefilament material by the compaction unit to form at least one compactedfilament material. In some embodiments, the compaction unit comprises arigid body, one or more idler rollers, at least one freely suspendedroller, a coolant unit, or a combination thereof. In some embodiments,the at least one freely suspended roller has a diameter from about 1millimeter to 10 millimeter. In some embodiments, (b)-(d) of the methodfor printing at least a portion of a 3D object comprises using one ormore sensors to measure one or more temperature(s) along the at leastone filament material. In some embodiments, the one or more sensorscontrol intensities of the at least the first energy beam. In someembodiments, the one or more sensors is an optical pyrometer. In someembodiments, a real time simulation provides feedback control of a givenlocation, direction, or angle of the at least the first energy beamnormal to the substrate and/or along the substrate among one or morelocations, directions, or angles. In some embodiments, the at least thefirst energy beam heats the at least one filament material withoutmelting a deposited portion of the at least one filament material. Insome embodiments, the at least the first energy beam heats and melts adeposited portion of the at least one filament material at a givenlocation among the one or more locations. In some embodiments, alteringa direction of a major axis of the at least the first energy beamrelative to the substrate or the at least one filament material alters afluence of the at least the first energy beam.

In another aspect, the present disclosure provides a system for printingat least a portion of a three-dimensional (3D) object, comprising asource of at least one filament material that is configured to supply atleast one filament material for generating the 3D object, a substratefor supporting at least the portion of the 3D object, and at least oneenergy source configured to deliver at least a first energy beam. Suchsystem may further comprise a controller operatively coupled to the atleast one energy source, wherein the controller is programmed to (i)receive, in computer memory, a model of the 3D object, (ii) subsequentto receiving the model of the 3D object, direct the at least onefilament material from the source of the at least one filament materialtowards the substrate that is configured to support the 3D object,thereby depositing a first layer corresponding to a portion of the 3Dobject adjacent to the substrate, which first layer is deposited inaccordance with the model of the 3D object, (iii) deposit a second layercorresponding to at least a portion of the 3D object, which second layeris deposited in accordance with the model of the 3D object, and (iv) useat least a first energy beam from at least one energy source toselectively melt at least a portion of the first layer and/or the secondlayer, thereby forming at least a portion of the 3D object. In someembodiments, the controller is further programmed to perform fuseddeposition modeling on (i)-(iii). In some embodiments, the controller isfurther programmed to deposit one or more additional layers adjacent tothe first layer prior to depositing the second layer. In someembodiments, the system for printing at least a portion of athree-dimensional (3D) object further comprises an opening that isconfigured to (i) receive the at least one filament material, and (ii)direct the at least one filament material towards the substrate.

In some embodiments, the system for printing at least a portion of athree-dimensional (3D) object further comprises a compaction unit forcompressing the at least one filament material along the substrate. Insome embodiments, the compaction unit comprises a rigid body, one ormore idler rollers, at least one freely suspended roller, a coolantunit, or any combination thereof. In some embodiments, the at least onefreely suspended roller has a diameter from about 1 millimeter to 10millimeter. In some embodiments, the system for printing at least aportion of a three-dimensional (3D) object further comprises one or moresensors to measure one or more temperature(s) along the at least onefilament material. In some embodiments, the one or more sensors is anoptical pyrometer. In some embodiments, the substrate comprises a driveunit for moving the substrate.

In some embodiments, the at least one filament material is a compositematerial. In some embodiments, the least one filament material is acontinuous fiber composite. In some embodiments, the continuous fibercomposite includes one or more members selected from the groupconsisting of glass, carbon, aramid, cotton, silicon carbide, polymer,wool, and metal. In some embodiments, the at least one filament materialhas a diameter from about 0.1 millimeters to 5 millimeters. In someembodiments, the at least one energy source is a laser and/or source ofa hot fluid.

In some embodiments, the system for printing at least a portion of athree-dimensional (3D) object further comprises an optical unit in whichat least one energy source is in optical communication with one or morebeam splitters, which one or more beam splitters splits an energy beamfrom the at least one energy source into one or more beamlets that yieldthe at least said first energy beam. In some embodiments, the opticalunit comprises one or more elements selected from the group consistingof one or more beam splitters, one or more focusing lenses, and one ormore optical wedges. In some embodiments, the one or more beam splittersis selected from the group consisting of prism, glass sheet, plasticsheet, mirror, dielectric mirror, metal-coated mirror, partiallyreflecting mirror, pellicles, micro-optic beam splitters, waveguide beamsplitters, beam splitter cubes, fiber-optic beam splitter, and anycombination thereof. In some embodiments, the one or more optical wedgesis a Risley prism pair. In some embodiments, the one or more opticalwedges have a refractive index of at least about 1. In some embodiments,the one or more optical wedges comprise a first optical wedge and asecond optical wedge. In some embodiments, the one or more opticalwedges has a diameter from about 0.1 inches to 1 inch. In someembodiments, the controller further comprises a real time simulationprogram for providing feedback during printing of said 3D object. Insome embodiments, the real time simulation program is a feedback controlsystem.

In another aspect, the present disclosure provides a system for printingat least a portion of a three-dimensional (3D) object, comprising asource of at least one filament material that is configured to supply atleast one filament material for generating the 3D object, a substratefor supporting at least the portion of the 3D object, and at least oneenergy source configured to deliver at least a first energy beam. Suchsystem may further comprise a controller operatively coupled to the atleast one energy source, wherein the controller is programmed to (i)receive, in computer memory, a model of the 3D object, (ii) subsequentto receiving the model of the 3D object, direct the at least onefilament material from the source of the at least one filament materialtowards the substrate that is configured to support the 3D object,thereby depositing a first layer corresponding to a portion of the 3Dobject adjacent to the substrate, which first layer is deposited inaccordance with the model of the 3D object, (iii) use at least a firstenergy beam from at least one energy source to melt at least a portionof the first layer, and (iv) deposit a second layer corresponding to atleast said portion of the 3D object, which second layer is deposited inaccordance with the model of the 3D object, thereby generating at leasta portion of the 3D object. In some embodiments, the controller isfurther programmed to perform fused deposition modeling on (i)-(iv). Insome embodiments, the controller is programmed further to repeat(ii)-(iv) one or more times. In some embodiments, system for printing atleast a portion of the 3D object further comprises an opening configuredto (i) receive the at least one filament material, and (ii) direct theat least one filament material towards the substrate.

In some embodiments, system for printing at least a portion of the 3Dobject further comprises a compaction unit for compressing the at leastone filament material along the substrate. In some embodiments, thecompaction unit comprises a rigid body, one or more idler rollers, atleast one freely suspended roller, a coolant unit, or any combinationthereof. In some embodiments, the at least one freely suspended rollerhas a diameter from about 1 millimeter to 10 millimeter. In someembodiments, system for printing at least a portion of the 3D objectfurther comprises one or more sensors to measure one or moretemperature(s) along the at least one filament material. In someembodiments, the one or more sensors is an optical pyrometer. In someembodiments, the substrate comprises a drive unit for moving thesubstrate.

In some embodiments, the at least one filament material is a compositematerial. In some embodiments, the at least one filament material is acontinuous fiber composite. In some embodiments, the continuous fibercomposite is selected from the group consisting of glass, carbon,aramid, cotton, silicon carbide, polymer, wool, metal, or anycombination thereof. In some embodiments, the at least one filamentmaterial has a diameter from about 0.1 millimeters to 5 millimeters. Insome embodiments, the at least one energy source is a laser and/orsource of a hot fluid.

In some embodiments, system for printing at least a portion of the 3Dobject further comprises an optical unit in which at least one energysource is in optical communication with one or more beam splitters,which one or more beam splitters splits an energy beam from the at leastone energy source into one or more beamlets that yield the at least thefirst energy beam. In some embodiments, the optical unit comprises oneor more elements selected from the group consisting of one or more beamsplitters, one or more focusing lenses, and one or more optical wedges.In some embodiments, the one or more beam splitters is selected from thegroup consisting of prism, glass sheet, plastic sheet, mirror,dielectric mirror, metal-coated mirror, partially reflecting mirror,pellicles, micro-optic beam splitters, waveguide beam splitters, beamsplitter cubes, fiber-optic beam splitter, and any combination thereof.In some embodiments, the one or more optical wedges is a Risley prismpair. In some embodiments, the one or more optical wedges have arefractive index of at least about 1. In some embodiments, the one ormore optical wedges comprise a first optical wedge and a second opticalwedge. In some embodiments, the one or more optical wedges has adiameter from about 0.1 inches to 1 inch. In some embodiments, thecontroller further comprises a real time simulation program forproviding feedback during printing of the 3D object. In someembodiments, the real time simulation program is a feedback controlunit.

Additional aspects and advantages of the present disclosure may becomereadily apparent to those skilled in this art from the followingdetailed description, wherein only illustrative embodiments of thepresent disclosure are shown and described. As will be realized, thepresent disclosure is capable of other and different embodiments, andits several details are capable of modifications in various obviousrespects, all without departing from the disclosure. Accordingly, thedrawings and description are to be regarded as illustrative in nature,and not as restrictive.

INCORPORATION BY REFERENCE

All publications and patent applications mentioned in this specificationare herein incorporated by reference to the same extent as if eachindividual publication or patent application was specifically andindividually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings (also “figure” and “FIG.” herein), of which:

FIG. 1A illustrates an example system that may be used to produce athree-dimensional object with extrusion having any desired shape, size,and structure using a modulated energy beam angled by optical wedges;

FIG. 1B illustrates an example system that may be used to produce athree-dimensional object with extrusion having any desired shape, size,and structure using a hot fluid (e.g., air) energy source;

FIG. 1C illustrates an example system that may be used to produce athree-dimensional object without extrusion having any desired shape,size, and structure using a hot fluid (e.g., air) energy source;

FIG. 2 shows an example system that may be used to produce athree-dimensional object having any desired shape, size, and structureusing an energy source and compaction unit;

FIG. 3 shows an example optical system for splitting and directing lightbeams at various angles to the plane of the substrate;

FIG. 4 illustrates a real time simulation feedback program forpropagation of the energy beams; and

FIG. 5 illustrates a computer control system that is programmed orotherwise configured to implement methods provided herein.

DETAILED DESCRIPTION

While various embodiments of the invention have been shown and describedherein, it will be obvious to those skilled in the art that suchembodiments are provided by way of example only. Numerous variations,changes, and substitutions may occur to those skilled in the art withoutdeparting from the invention. It should be understood that variousalternatives to the embodiments of the invention described herein may beemployed.

The term “three-dimensional printing” (also “3D printing”), as usedherein, generally refers to a process or method for generating a 3D part(or object). For example, 3D printing may refer to sequential additionof material layer or joining of material layers or parts of materiallayers to form a three-dimensional (3D) part, object, or structure, in acontrolled manner (e.g., under automated control). In the 3D printingprocess, the deposited material can be fused, sintered, melted, bound orotherwise connected to form at least a part of the 3D object. Fusing thematerial may include melting or sintering the material. Binding cancomprise chemical bonding. Chemical bonding can comprise covalentbonding. Examples of 3D printing include additive printing (e.g., layerby layer printing, or additive manufacturing). The 3D printing mayfurther comprise subtractive printing.

The term “part,” as used herein, generally refers to an object. A partmay be generated using 3D printing methods and systems of the presentdisclosure. A part may be a portion of a larger part or object, or anentirety of an object. A part may have various form factors, as may bebased on a model of such part. Such form factors may be predetermined.

The term “composite material,” as used herein, generally refers to amaterial made from two or more constituent materials with differentphysical or chemical properties that, when combined, produce a materialwith characteristics different from the individual components.

The term “fuse”, as used herein, generally refers to binding,agglomerating, or polymerizing. Fusing may include melting, softening orsintering. Binding may comprise chemical binding. Chemical binding mayinclude covalent binding. The energy source resulting in fusion maysupply energy by a laser, a microwave source, source for resistiveheating, an infrared energy (IR) source, a ultraviolet (UV) energysource, hot fluid (e.g., hot air), a chemical reaction, a plasma source,a microwave source, an electromagnetic source, or an electron beam.Resistive heating may be joule heating. A source for resistive heatingmay be a power supply. The hot fluid can have a temperature greater than25° C., or greater than or equal to about 40° C., 50° C., 60° C., 70°C., 80° C., 90° C., 100° C., 150° C., 200° C., 250° C., 300° C., 350°C., 400° C., 450° C., 500° C., or higher. The hot fluid may have atemperature that is selected to soften or melt a material used to printan object. The hot fluid may have a temperature that is at or above amelting point or glass transition point of a polymeric material. The hotfluid can be a gas or a liquid. In some examples, the hot fluid is air.

The term “adjacent” or “adjacent to,” as used herein, generally refersto ‘on,’ ‘over,’ ‘next to,’ ‘adjoining,’ ‘in contact with,’ or ‘inproximity to.’ In some instances, adjacent components are separated fromone another by one or more intervening layers. The one or moreintervening layers may have a thickness less than about 10 micrometers(“microns”), 1 micron, 500 nanometers (“nm”), 100 nm, 50 nm, 10 nm, 1nm, 0.5 nm or less. For example, a first layer adjacent to a secondlayer can be on or in direct contact with the second layer. As anotherexample, a first layer adjacent to a second layer can be separated fromthe second layer by at least a third layer.

Examples of 3D printing methodologies comprise extrusion, wire,granular, laminated, light polymerization, VAT photopolymerization,material jetting, binder jetting, sheet lamination, directed energydeposition, or power bed and inkjet head 3D printing. Extrusion 3Dprinting can comprise robo-casting, fused deposition modeling (FDM) orfused filament fabrication (FFF). Wire 3D printing can comprise electronbeam freeform fabrication (EBF3). Granular 3D printing can comprisedirect metal laser sintering (DMLS), electron beam melting (EBM),selective laser melting (SLM), selective heat sintering (SHS), orselective laser sintering (SLS). Power bed and inkjet head 3D printingcan comprise plaster-based 3D printing (PP). Laminated 3D printing cancomprise laminated object manufacturing (LOM). Light polymerized 3Dprinting can comprise stereolithography (SLA), digital light processing(DLP) or laminated object manufacturing (LOM).

Examples of methods, systems and materials that may be used to create orgenerate objects or parts herein are provided in U.S. Patent PublicationNos. 2014/0232035, 2016/0176118, and U.S. patent application Ser. Nos.14/297,185, 14/621,205, 14/623,471, 14/682,067, 14/874,963, 15/069,440,15/072,270, 15/094,967, each of which is entirely incorporated herein byreference.

Three-dimensional printing may be performed using various materials. Theform of the build materials that can be used in embodiments of theinvention include, without limitation, filaments, sheets, powders, andinks. In some examples, a material that may be used in 3D printingincludes a polymeric material, elemental metal, metal alloy, a ceramic,composite material, an allotrope of elemental carbon, or a combinationthereof. The allotrope of elemental carbon may comprise amorphouscarbon, graphite, graphene, diamond, or fullerene. The fullerene may beselected from the group consisting of a spherical, elliptical, linear,tubular fullerene, and any combination thereof. The fullerene maycomprise a buck ball or a carbon nanotube. The material may comprise anorganic material, for example, a polymer or a resin. The material maycomprise a solid or a liquid. The material may include one or morestrands or filaments. The solid material may comprise powder material.The powder material may be coated by a coating (e.g., organic coatingsuch as the organic material (e.g., plastic coating)). The powdermaterial may comprise sand. The material may be in the form of a powder,wire, pellet, or bead. The material may have one or more layers. Thematerial may comprise at least two materials. In some cases, thematerial includes a reinforcing material (e.g., that forms a fiber). Thereinforcing material may comprise a carbon fiber, Kevlar®, Twaron®,ultra-high-molecular-weight polyethylene, or glass fiber.

Prior to printing the part or object, a computer aided design (CAD)model can be optimized based on specified requirements. For example, theCAD model may comprise a geometry “envelop”. A geometry envelop may bean initial shell design of the three-dimensional part comprising designrequirements and geometric features. The geometry of the CAD model maybe received by way of I/O devices. Design requirements can be selectedfrom the group consisting of strength, structural deflections, stress,strain, tension, shear, load capacity, stiffness, factor-of safety,weight, strength to weight ratio, envelop geometry, minimal print time,thermal performance, electrical performance, porosity, infill, number ofshells, layer height, printing temperature, extruder temperature, soliddensity, melt density, printing speed, print head movement speed, andany combination thereof.

The CAD model may be initially partitioned according to user input andbuilt in tool path generator rules to produce numerical controlprogramming codes of the partitioned computer model. Partitioning cangenerate one or more parameters for printing the part. The One or moreparameters may be selected from the group consisting of filamentdiameter, layer thickness, infill percentage, infill pattern, rasterangle, build orientation, printed material width, extrudate width, layerheight, shell number, infill overlap, grid spacing, and any combinationthereof. Partitioning can also generate one or more numerical controlprogramming code of the partitioned computer model. The numericalcontrol programming code can comprise G-code files and intermediatefiles. G-code files may be a numerical control programming language andcan be used in computer-aided manufacturing as a way of controllingautomated machine tools. The actions controlled by the G-code maycomprise rapid movement, controlled feed in an arc or straight line,series of controlled feed movements, switch coordinate systems, and aset of tool information. Intermediate files may comprise supplementalfiles and tools for a primary build output. Additionally, intermediatefiles can comprise automatically generated source files or build outputfrom helper tools. The information from the G-code files and theintermediate files may be extracted to determine the geometry of thethree-dimensional printed part.

The 3D object may have a 3D solid model created in CAD software. Such 3Dobject can be sliced using conventional algorithms as are known in theart to generate a series of two dimensional (2D) layers representingindividual transverse cross sections of the 3D object, whichcollectively depict the 3D object. The 2D slice information for thelayers may be sent to the controller and stored in memory. Suchinformation can control the process of fusing particles into a denselayer according to the modeling and inputs obtained during the buildprocess.

Prior to printing the three-dimensional object, a model, in computermemory, of the part for three-dimensional printing may be received froma material. The material can comprise a matrix and fiber material.Additionally, in computer memory, one or more properties for thematerial may be received. Using the model, a print head tool path may bedetermined for use during the three-dimensional printing of the part. Avirtual mesh of analytic elements may be generated within the model ofthe part and a trajectory of at least one stiffness-contributing portionof the material may be determined based at least in part on the printhead tool path, wherein the trajectory of the at least onestiffness-contributing portion is determined through each of theanalytic elements in the virtual mesh. Next, one or more computerprocessors may be used to determine a performance of the part based atleast in part on the one or more properties received and the trajectoryof the at least one stiffness-contributing portion. The performance ofthe part may be electronically outputted. The three-dimensional objectmay then be printed along the print head tool path.

The present invention may provide ways to improve the mechanical,thermal, and electrical properties of additively manufactured parts. Alladditive manufacturing approaches build up an object in a layer-by-layerfashion. In other words, the layers of build material are deposited oneon top of the next, such that a successive layer of build material isdeposited upon a previously deposited/constructed layer that has cooledbelow its melting temperature. The print head may comprise three or moreaxes or degrees of freedom so that the print head can move in the +Xdirection, the −X direction, the +Y direction, the −Y direction, the +Zdirection, the −Z direction, or any combination thereof. The print headmay be configured as a six-axis robotic arm. Alternatively, the printhead may be configured as a seven-axis robotic arm. The print head maybe placed at any location in the build volume of the 3D object, from anyapproach angle.

In accordance with embodiments of the invention, a system for additivemanufacturing processes provides localized heating to create a “meltpool” in the current layer or segment of deposited build material priorto depositing the next segment or layer. The melt pool can span theentire thickness of the printed segment, thereby increasing the adhesionacross segments built in the same layer. The melt pool can span aportion of the thickness of the printed segment. The melt pool mayincrease the diffusion and mixing of the build material between adjacentlayers (across the Z direction) as compared to current methods, whichdeposit a subsequent layer of build material on top of a layer of buildmaterial that is below its melting temperature. The increased diffusionand mixing resulting from the melt pool can increase the chemical chainlinkage/bonding and chemical chain interactions between the two layers.This can result in increases in the build-material adhesion in the Zdirection, thereby enhancing mechanical, thermal, and electricalproperties. The melt pool may also reduce void space and porosity in thebuild object. Among any other benefits, this decrease in porosity alsocontributes somewhat to the aforementioned improvement in mechanical,thermal, and electrical properties.

Before depositing a layer of material on an underlying layer in a buildobject, the portion of the underlying layer on which the subsequentlayer is to be deposited may be melted, creating a “melt pool.” The meltpool can be created using an energy source, such as, without limitation,by a laser, a microwave source, a resistive heating source, an infraredenergy source, a UV energy source, hot fluid, a chemical reaction, aplasma source, a microwave source, an electromagnetic source, or anelectron beam. Resistive heating may be joule heating. A source forresistive heating may be a power supply. The applied energy is primarilya function of the chemical composition of the build material, such asthe build material's thermal conductivity, heat capacity, latent heat offusion, melting point, and melt flow viscosity.

Prior to printing the 3D object, a request for production of a requested3D object may be received from a customer. The method may comprisepackaging the three dimensional object. After printing of the 3D object,the printed three dimensional object may be delivered to the customer.

In an aspect, the present disclosure provides for method for printing atleast a portion of a 3D object. In computer memory, a model of the 3Dobject may be received. Subsequent to receiving the model of the 3Dobject, at least one filament material may be directed from a source ofat least one filament material towards a substrate that is configured tosupport the 3D object, thereby depositing a first layer corresponding toa portion of the 3D object adjacent to the substrate. The first layermay be deposited in accordance with the model of the 3D object. At leastone filament material may be directed from the source to an opening. Atleast one filament material can be directed from the opening towards thesubstrate. Next, a second layer of at least a portion of the 3D objectmay be deposited. The second layer can be deposited in accordance withthe model of the 3D object. At least a first energy beam may be usedfrom at least one energy source to selectively melt at least a portionof the first layer and/or the second layer, thereby forming at least aportion of the 3D object. One or more additional layers may be furtherdeposited adjacent to the first layer prior to depositing the secondlayer. In some cases, fused deposition modeling may be performed whenprinting the 3D object. In other cases, the 3D object may be printedwith extrusion. In some cases, the 3D object may be printed withoutextrusion.

The layered structure can comprise substantially repetitive layers. Thelayers may have an average layer size of at least about 0.5 μm, 1 μm, 5μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, 450 μm, 500 μm, 1mm, 25 mm, 50 mm, 100 mm, 500 mm, or 1 m. The layers may have an averagelayer size of at most about 50 m, 1 m, 500 mm, 100 mm, 50 mm, 25 mm, 1mm, 500 μm, 450 μm, 400 μm, 350 μm, 300 μm, 250 μm, 200 μm, 150 μm, 100μm, 90 μm, 80 μm, 70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 20 μm, or 10 μm.The layers may have an average layer size of any value between theaforementioned values of layer size. For example, the substantiallyrepetitive microstructure may have an average layer size from about 0.5μm to about 500 mm, from about 15 μm to about 100 μm, from about 5 μm toabout 300 μm, from about 20 μm to about 90 μm, or from about 10 μm toabout 70 μm. The layered structure can be indicative of layereddeposition. The layered structure can be indicative of solidification ofmelt pools formed during a three dimensional printing process. Thestructure indicative of a three dimensional printing process cancomprise substantially repetitive variation comprising: variation ingrain orientation, variation in material density, variation in thedegree of compound segregation to grain boundaries, variation in thedegree of element segregation to grain boundaries, variation in materialphase, variation in metallurgical phase, variation in material porosity,variation in crystal phase, or variation in crystal structure. The meltpools may be indicative of an additive manufacturing process comprisingstereolithography (SLA), selective laser melting (SLM), selective lasersintering (SLS), digital light processing (DLP), electron beam melting(EBM), laminated object manufacturing (LOM), binder jetting (BM),material jetting/wax casting (MJ), direct metal laser sintering (DMLS),or fused deposition modeling (FDM). The melt pools may be indicative ofan additive manufacturing process comprising selective energy melting.

The source of at least one filament material may be configured to supplyat least one filament material for generating the three-dimensionalobject. The at least one filament material may be a composite material,such as a continuous fiber composite. The filament material may be nanomilled, short, long, continuous, or a combination thereof. Thecontinuous fiber composite may be a continuous core reinforced filament.The continuous core reinforced filament can comprise a towpreg that issubstantially void free and includes a polymer that coats or impregnatesan internal continuous core. Depending upon the particular embodiment,the core may be a solid core or it may be a multi-strand core comprisingmultiple strands. The continuous fiber composite may be selected fromthe group consisting of glass, carbon, aramid, cotton, silicon carbide,polymer, wool, metal, and any combination thereof.

The filament material may incorporate one or more additional materials,such as resins and polymers. For example, appropriate resins andpolymers include, but are not limited to, acrylonitrile butadienestyrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI),Polyaryletherketone (PAEK), Polyether ether ketone (PEEK), PolyacticAcid (PLA), Liquid Crystal Polymer, polyamide, polyimide, polyphenylenesulfide, polyphenylsulfone, polysulfone, polyether sulfone,polyethylenimine, polytetrafluoroethylene, polyvinylidene, and variousother thermoplastics. The core of the continuous fiber composite may beselected to provide any desired property. Appropriate core fiber orstrands include those materials which impart a desired property, such asstructural, conductive (electrically and/or thermally), insulative(electrically and/or thermally), optical and/or fluidic transport. Suchmaterials include, but are not limited to, carbon fibers, aramid fibers,fiberglass, metals (such as copper, silver, gold, tin, and steel),optical fibers, and flexible tubes. The core fiber or strands may beprovided in any appropriate size. Further, multiple types of continuouscores may be used in a single continuous core reinforced filament toprovide multiple functionalities such as electrical and opticalproperties. A single material may be used to provide multiple propertiesfor the core reinforced filament. For example, a steel core may be usedto provide both structural properties as well as electrical conductivityproperties.

Alternatively, the filament material may comprise metal particlesinfused into a binder matrix. The metal particles may be metal powder.The binder matrix may include resins or polymers. Additionally, suchbinder matrix can be used a delivery device for the metal particles.Once the filament material is deposited onto the base, one or moreenergy sources can heat and melt the binder matrix, leaving the metalparticles to melt and fuse into larger metal particles. Such energysources may be without limitation, by a laser, a microwave source, aresistive heating source, an infrared energy source, a UV energy source,hot fluid, a chemical reaction, a plasma source, a microwave source, anelectromagnetic source, or an electron beam. Resistive heating may bejoule heating. A source for resistive heating may be a power supply. Theat least one filament material may be a metal filament. The at least onefilament material may be a metal filament composite. The deposited atleast one filament material may be subjected to resistive heating uponflow of an electrical current through the at least one filamentmaterial. The resistive heating may be sufficient to melt at least aportion of the deposited at least one filament material. The at leastone filament material may be an electrode. The substrate may be anotherelectrode.

The one or more energy sources may also provide localized heating tocreate a “melt pool” in the current layer or segment of the depositedbuild material prior to depositing the next segment or layer. The meltpool can increase diffusion and mixing of the build material betweenadjacent layers (e.g., across a direction orthogonal to the layers) ascompared to other methods which deposit a subsequent layer of buildmaterial on top of a layer of build material that is below its meltingtemperature.

The increased diffusion and mixing resulting from the melt pool mayincrease the chemical chain linkage, bonding, and chemical chaininteractions between the two layers. This can result in increasing thebuild-material adhesion in the Z direction, thereby enhancingmechanical, thermal, and electrical properties of the three-dimensionalobject. The melt pool can also reduce the void space and porosity in thebuild object. Among other benefits, this decrease in porosity may alsocontribute to the aforementioned improvement in mechanical, thermal, andelectrical properties.

The at least one filament material may have a cross sectional shapeselected from the group consisting of circle, ellipse, parabola,hyperbola, convex polygon, concave polygon, cyclic polygon, equilateralpolygon, equiangular polygon, regular convex polygon, regular starpolygon, tape-like geometry, and any combination thereof. Such filamentmaterial can have a diameter of at most about 0.1 millimeters (mm), atmost about 0.2 mm, at most about 0.3 mm, at most about 0.4 mm, at mostabout 0.5 mm, at most about 0.6 mm, at most about 0.7 mm, at most about0.8 mm, at most about 0.9 mm, at most about 1 mm, at most about 2 mm, atmost about 3 mm, at most about 4 mm, at most about 5 mm, at most about10 mm, or at most about 20 mm.

Various modifiers within the layers themselves may be used which areselectively printed onto specific regions of the 3D object in order toimpart various desirable mechanical, chemical, magnetic, electrical orother properties to the 3D object. Such modifiers may be selected fromthe group consisting of thermal conductors and insulators, dielectricpromoters, electrical conductors and insulators, locally-containedheater traces for multi-zone temperature control, batteries, andsensors. In some embodiments, at least one print head can be may be usedfor printing such modifiers. As desired, such modifiers can be printedbefore at least a first energy beam is directed onto at least a portionof the first layer and/or second layer. Alternatively, such modifiersmay be printed over a layer that has been melted, before filamentmaterial for the next layer is deposited.

For example, when printing a polyimide part from commercially availablea filament comprising polyimide, an array of electrically conductivetraces may be assimilated as an antenna to selectively absorbradiofrequency (RF) radiation within a specific and predeterminedfrequency range. The 3D object CAD model and software can designate as asub-part the layer(s) that comprise the traces for modified properties(high electrical conductivity). Alternatively, if these portions of thelayer entail different levels of energy for inducing fusion, compared toother regions having only the primary material, the CAD model and designof the 3D object may be adjusted accordingly.

After deposition of a first layer and/or a second layer of at least aportion of the 3D object, and before fusion is induced, the filamentmaterial may be preheated to a temperature sufficient to reduceundesirable shrinkage and/or to minimize the laser energy needed to meltthe next layer. For example, the preheating may be accomplished usingthe infrared heater attached to substrate or through other apparatusesof directing thermal energy within an enclosed space around thesubstrate. Alternatively, the preheating can be accomplished usingenergy beam melting by defocusing the energy beam and rapidly scanningit over the deposited first layer and or second of at least a portion ofthe 3D object.

In some embodiments, at least a first energy beam from at least oneenergy source may be used to selectively heat and/or melt at least aportion of the first layer and/or the second layer, thereby forming atleast a portion of the 3D object. The energy source may be selected fromthe group consisting of a laser, a microwave source, a resistive heatingsource, an infrared energy source, a UV energy source, hot fluid, achemical reaction, a plasma source, a microwave source, anelectromagnetic source, an electron beam, or any combination thereof.Resistive heating may be joule heating. A source for resistive heatingmay be a power supply. The at least one filament material may be a metalfilament. The at least one filament material may be a metal filamentcomposite. The deposited at least one filament material may be subjectedto resistive heating upon flow of an electrical current through the atleast one filament material. The resistive heating may be sufficient tomelt at least a portion of the deposited at least one filament material.The at least one filament material may be an electrode. The substratemay be another electrode.

The energy source may be a function of the chemical composition of thebuild material, such as the build material's thermal conductivity, heatcapacity, latent heat of fusion, melting point, and melt flow viscosity.The at least one energy source may be a laser. The laser may be selectedfrom the group consisting of gas lasers, chemical lasers, dye lasers,metal-vapor lasers, solid-state lasers, semiconductor lasers, freeelectron laser, gas dynamic laser, nickel-like samarium laser, Ramanlaser, nuclear pump laser, and any combination thereof. Gas lasers maycomprise one or more of helium-neon laser, argon laser, krypton laser,xenon ion laser, nitrogen laser, carbon dioxide laser, carbon monoxidelaser, and excimer laser. Chemical lasers may be selected from the groupconsisting of hydrogen fluoride laser, deuterium fluoride laser,chemical oxygen-iodine laser, all gas-phase iodine laser, and anycombination thereof. Metal-vapor lasers can comprise one or more ofhelium-cadmium, helium mercury, helium selenium, helium silver,strontium vapor laser, neon-copper, copper vapor laser, gold vaporlaser, and manganese vapor laser. Solid-state lasers may be selectedfrom the group consisting of ruby laser, neodymium-doped yttriumaluminium garnet laser, neodymium and chromium-doped yttrium aluminiumgarnet laser, erbium-doped yttrium aluminium garnet laser,neodymium-doped yttrium lithium fluoride laser, neodymium doped yttriumothovanadate laser, neodymium doped yttrium calcium oxoborate laser,neodymium glass laser, titanium sapphire laser, thulium yttriumaluminium garnet laser, ytterbium yttrium aluminium garnet laser,ytterbium:₂O₃ (glass or ceramics) laser, ytterbium doped glass laser(rod, plate/chip, and fiber), holmium yttrium aluminium garnet laser,chromium zinc selenium laser, cerium doped lithium strontium (orcalcium) aluminum fluoride laser, Promethium 147 doped phosphate glasssolid-state laser, chromium doped chrysoberyl (alexandrite) laser,erbium doped and erbium-ytterbium codoped glass lasers, trivalenturanium doped calcium fluoride solid-state laser, divalent samariumdoped calcium fluoride laser, FARBE center laser, and any combinationthereof. Semiconductor laser may comprise one or more of semiconductorlaser diode laser, gallium nitride laser, indium gallium nitride laser,aluminium gallium indium phosphide laser, aluminium gallium arsenidelaser, indium gallium arsenide phosphide laser, lead salt laser,vertical cavity surface emitting laser, quantum cascade laser, andhybrid silicon laser.

The melting temperature of the at least one filament material can be atleast about 150° C., at least about 200° C., at least about 250° C., atleast about 300° C., at least about 350° C., at least about 400° C., atleast about 450° C. The sintering temperature can be at most about 150°C., at most about 200° C., at most about 250° C., at most about 300° C.,at most about 350° C., at most about 400° C. The method may furthercomprise separating the remainder of the layer that did not fuse andsolidify to form at least a portion of the three dimensional object,from the portion.

The at least one energy beam from the energy source may be directed tothe at least one portion of the 3D object adjacent to the substrate.Such energy beams may be sufficient to induce fusion of particles of thefilament material within the desired cross-sectional geometry of the atleast one portion of the 3D object. As the energy dissipates withcooling, atoms from neighboring particles may fuse together. In someembodiments, the at least one energy beam results in the fusion ofparticles of filament material both within the same layer and in thepreviously formed and resolidified adjoining layer(s) such that fusionis induced between at least two adjacent layers of the part, such asbetween at least one filament material in a deposited unfused layer anda previously-fused adjacent layer. This process is then repeated overmultiple cycles as each part layer is added, until the full 3D object isformed.

In some cases, to create a melt pool large enough to span the width ofthe filament material segment, multiple energy sources or a combinationof energy sources may be required. When multiple energy sources areused, the energy sources may be the same energy source. Alternatively,the multiple energy sources may be different energy sources. The energysource(s) may be separate from the system for printing at least aportion of the 3D object. In some other embodiments, the energysource(s) may be integrated with such system. For example, in oneembodiment, hot fluid may be channeled through the deposition nozzle.Because the material filament can flow in the melt pool, features of the3D object being built can be altered. In some embodiments, the melt poolmay be formed within the build object, such that a melt pool is notformed near the perimeters thereof. To accomplish this, the energysource may be turned off when the perimeters of the object are beingbuilt. In such embodiments, the geometrical tolerance of the buildobject may be maintained while the interior of the object has enhancedinterlayer bonding. During printing, the filament material may beprinted in the X, Y, and Z directions in one segment or layer.

FIG. 1A illustrates an example system 100, which may be used to producea three-dimensional object having any desired shape, size, andstructure. The example system 100 may be an FDM system. In system 100,at least one filament material 101 from a source of the at least onefilament material may be directed to an opening through a passage of aprint head 103. Such a filament material can then be directed from theopening towards a substrate 106 that is configured to support the 3Dobject 105, thereby depositing a first layer corresponding to a portionof the 3D object. Such a filament material can be directed from theopening as an extrudate 113. During deposition of each layer, the printhead may move in the X and Y direction in accordance with the model ofthe 3D object. A second layer of at least a portion of the 3D object maythen be deposited. One or more additional layers may be depositedadjacent to the first layer prior to depositing the second layer. Theportion of the 3D object may comprise at least one layer 104. The system100 may comprise heater cartridges 102 with thermal control fromproportional-integral-derivative controller (PID controllers) connectedto thermocouples. The heater cartridges may function as a temperaturecontrol for the system 100. The one or more thermocouples can besituated at one or several locations to provide feedback to acontroller, such as a PID controller, and hence maintain temperature setpoints throughout a build. At least a first energy beam 109 from atleast one energy source may be used to selectively melt at least aportion of the first layer and/or the second layer, thereby forming atleast a portion of the 3D object. A part of the modulated energy beam109 may be focused by the focusing system 107, angled by the opticalwedges 108, and irradiated along the at least one filament material forthree-dimensional printing.

FIG. 1B illustrates another example system 115, which may be used toproduce a three-dimensional object having any desired shape, size, andstructure. The example system 115 may be an FDM system. In system 115,at least one filament material 101 from a source of the at least onefilament material may be directed to an opening through a passage of aprint head 103. Such a filament material can then be directed from theopening as an extrudate 113 and deposited as a first layer correspondingto a portion of the 3D object on the substrate 106. The substrate can beconfigured to support the 3D object 105. During deposition of eachlayer, the print head may move in the X and Y direction in accordancewith the model of the 3D object. Next, a second layer of at least aportion of the 3D object can be deposited. One or more additional layersmay be deposited adjacent to the first layer prior to depositing thesecond layer. The portion of the 3D object may comprise at least onelayer 104. The system 115 may comprise heater cartridges 102 withthermal control from PID controllers connected to thermocouples. Theheater cartridges may function as a temperature control for the system115. The one or more thermocouples can be situated at one or severallocations to provide feedback to a controller, such as a PID controller,and hence maintain temperature set points throughout a build. At least afirst energy beam 112 from at least one energy source may be used toselectively melt at least a portion of the first layer and/or the secondlayer, thereby forming at least a portion of the 3D object. The energysource may be a convective fluid source. The at least a first energybeam may be at least a first hot fluid (e.g., air) beam. The print headmay be protected with a jacket cover 111 to contain and direct the flowof the hot fluid towards the layers of the at least a portion of the 3Dobject. The top view 120 of the extrudate 113 deposition through thenozzle 114 illustrates the even distribution of the convective hot fluid112 around the extrudate 113.

FIG. 1C illustrates another example system 125, which may be used toproduce a three-dimensional object having any desired shape, size, andstructure. The example system 125 may be a continuous filament passthrough system for printing. The continuous filament pass through systemmay comprise filament material deposition without extrusion. In system125, at least one filament material 101 from a source of the at leastone filament material may be directed to an opening through a passage ofa print head 103. Such a filament material can then be directed from theopening as a printed at one filament material 123 without extrusion anddeposited as a first layer corresponding to a portion of the 3D objecton the substrate 106. The substrate can be configured to support the 3Dobject 105. During deposition of each layer, the print head may move inthe X and Y direction in accordance with the model of the 3D object.Next, a second layer of at least a portion of the 3D object can bedeposited without extrusion. One or more additional layers may bedeposited without extrusion adjacent to the first layer prior todepositing the second layer. The portion of the 3D object may compriseat least one layer 104. The system 125 may comprise heater cartridges102 with thermal control from PID controllers connected tothermocouples. The heater cartridges may function as a temperaturecontrol for the system 125. The one or more thermocouples can besituated at one or several locations to provide feedback to acontroller, such as a PID controller, and hence maintain temperature setpoints throughout a build. At least a first energy beam 112 from atleast one energy source may be used to selectively melt at least aportion of the first layer and/or the second layer, thereby forming atleast a portion of the 3D object. The energy source may be a convectivefluid source. The at least a first energy beam may be at least a firsthot fluid (e.g., air) beam. The print head may be protected with ajacket cover 111 to contain and direct the flow of the hot fluid towardsthe layers of at least a portion of the 3D object. The top view 130 ofthe printed at one filament material 123 deposition through the printhead 103 illustrates the even distribution of the convective hot fluid112 around the printed at one filament material 123.

FIG. 2 illustrates another example system 200, which may be used toproduce a three-dimensional object having any desired shape, size, andstructure. System 200 may include an extender mechanism (or unit) 202comprising one or more rollers for directing at least one filamentmaterial 203 from a source of at least one filament material towards asubstrate 208. Such filament material may initially comprise anuncompressed cross section 201. The extender mechanism can include amotor for dispensing at least one filament material. This filamentmaterial may be directed from the source to an opening, such as a nozzle204, and can also be directed from the opening towards the substrate.The opening may receive at least one filament material, and can directsuch filament material towards the substrate. The substrate may beadjacent to which the 3D object is formed. Additionally, the substratecan include a drive mechanism (or unit) for moving the substrate.

Such filament material may also be directed to at least one freelysuspended roller 206, thereby depositing a first layer corresponding toa portion of the 3D object on the substrate. Next, the second layer ofat least a portion of the 3D object may be deposited. One or moreadditional layers can be deposited adjacent to the first layer prior todepositing the second layer. At least a first energy beam from at leastone energy source may selectively melt at least a portion of the firstlayer and/or the second layer, thereby forming at least a portion of the3D object. The energy beam may be a laser beam. The energy source may bea laser head that is mounted on a robot or similar mechanism thatswivels around the vertical axis enabling deposition in any direction inthe plane of deposition. At least one filament material may be fed intoa nozzle at an angle such that it is fed under at least one freelysuspended roller at a nip point 209 as the at least one freely suspendedroller presses this filament material exiting from the nozzle. The nippoint can be the point where such filament material meets the substrateand is pressed by the at least one freely suspended roller resulting ina compressed cross section 210.

The compaction unit may comprise at least one freely suspended rollerthat is supported by one or more idler rollers 205. The at least onefreely suspended roller may be designed to control the bend radii ofsuch filament material. At least a portion of the three-dimensionalobject may be generated from such filament material continuously uponsubjecting such deposited filament material to heating along the one ormore locations. The system 200 may further comprise a controlleroperatively coupled to at least one light source.

The at least one energy source may be in optical communication with oneor more beam splitters, which one or more beam splitters can split anenergy beam from at least one light source into one or more beamlets (orbeams) that yields at least the first energy beam. FIG. 3 illustrates anexample optical system 300 capable of receiving in an opening 301,splitting, and directing such energy beams at various angles to theplane of the substrate 208 of system 200. System 300 can comprise one ormore beam splitters 302, one or more focusing lenses 303, one or moreoptical wedges 304, and any combination thereof. The optical system 300may allow the energy beams to be aligned at any angle in the plane ofdeposition. The optical system may further comprise a beam expandingsystem and a spatial light modulator. At least the first energy beam maybe emitted by at least one light source and expanded by the beamexpanding system into parallel light beams having a large diameter bythe beam expanding system. Then, such parallel energy beams mayirradiate onto the one or more beam splitters. A part of the expandedenergy beams may reach a spatial modulator for modulation after passingthrough the beam splitter and the modulated energy beams can bereflected to the beam splitter. A part of the modulated energy beam maybe focused by the focusing system, angled by the optical wedges, andirradiated along the at least one filament material forthree-dimensional printing. The beam expanding system may comprise anegative lens and a positive lens. Furthermore, the spatial lightmodulator can be a reflector type digital micro-mirror device or a phasetype liquid crystal spatial light modulator.

One or more beam splitters may be selected from the group consisting ofprism, glass sheet, plastic sheet, mirror, dielectric mirror,metal-coated mirror, partially reflecting mirror, pellicles, micro-opticbeam splitters, waveguide beam splitters, beam splitter cubes,fiber-optic beam splitter, and any combination thereof. One or moreoptical wedges may be in optical communication with one or more beamsplitters, which one or more optical wedges form at least the firstlight beam. Such optical wedges can form at least the first light beamin a uniform orientation. The one or more beamlets may pass through oneor more focusing lenses prior to passing through at least one or moreoptical wedges. Such beamlets may have an elliptical polarization. Theone or more beamlets may comprise a minor axis of at least about 0.5 mm,at least about 1 mm, at least about 2 mm, at least about 3 mm, at leastabout 4 mm, at least about 5 mm, at least about 6 mm, at least about 7mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, orat least about 15 mm. The one or more beamlets may also comprise a majoraxis of at least about 5 mm, at least about 10 mm, at least about 15 mm,at least about 20 mm, at least about 25 mm, at least about 30 mm, atleast about 35 mm, at least about 40 mm, at least about 45 mm, or atleast about 50 mm. Such light beams can cover at least a portion of atleast one filament material. The one or more focusing lenses may be usedto adjust a ratio of the minor axis to the major axis of the one or morebeamlets.

Optical wedges may alter the path of the beam from vertical to any anglefor uniform heating of the filament material. The one or more opticalwedges can also direct an optical path of at least the first light beamof a given location, direction, or angle normal to the substrate and/oralong the substrate among one or more locations, directions, or angles.Such a direction of one or more optical wedges can allow for control ofthe heat from the light beam along the at least one filament material.

The one or more optical wedges can be used in combination with one ormore of dispersive prism, reflective prism, beam-splitting prism,polarizing prism, or deflecting prisms. Dispersive prisms may be used tobreak up light into its constituent spectral colors because therefractive index depends on frequency. Examples of dispersive prismsinclude Triangular prism, Abbe prism, Pellin-Broca prism, Amici prism,Compound prism, or Grism prism. Reflective prisms can be used to reflectlight, in order to flip, invert, rotate, deviate or displace the lightbeam. Examples of reflective prisms include Porro prism, Porro-Abbeprism, Amici roof prism, Pentaprism, Roof Pentaprism, Abbe-Koenig prism,Schmidt-Pechan prism, Bauernfeind prism, Dove prism, or Retroreflectorprism. Some reflective prisms may be used for splitting a beam into twoor more beams. Beam-splitting prisms may be a beam splitter cube or adichronic prism. Polarizing prisms can split a beam of light intocomponents of varying polarization. Examples of polarizing prisms may beNicol prism, Wollaston prism, Nomarski prism, Rochon prism, Senarmontprism, Glan-Foucault prism, Glan-Taylor prism, or Glan-Thompson prism.Deflecting prisms may be one or more of a Risley prism pair, Rhomboidprisms, or Deck prisms. Wedge prisms may be used to deflect a beam oflight by a fixed angle. A pair of such prisms can be used for beamsteering; by rotating the prisms the beam can be deflected into anydesired angle. The deflecting prism may be a Risley prism pair. Twowedge prisms can also be used as an anamorphic pair to change the shapeof a beam. For example, this may be used to generate a round beam fromthe elliptical output of a laser diode.

One or more optical wedges can have a refractive index of at least about0.5, at least about 1, at least about 1.1, at least about 1.2, at leastabout 1.3, at least about 1.4, at least about 1.5, at least about 1.6,at least about 1.7, at least about 1.8, at least about 1.9, at leastabout 2.5, at least about 3, at least about 4, or at least about 5. Suchoptical wedges can have a diameter of at most about 0.1 inches (in), atmost about 0.2 in, at most about 0.3 in, at most about 0.4 in, at mostabout 0.5 in, at most about 0.6 in, at most about 0.7 in, at most about0.8 in, at most about 0.9 in, at most about 1 in, at most about 2 in, atmost about 3 in, at most about 4 in, or at most about 5 in.

In some embodiments, at least the first energy beam may be incident onat least one filament material and on the substrate. Such energy beamsmay be directed along a given angle among one or more angles relative tothe dispensing route of at least one filament material. The one or moreoptical wedges can comprise a first optical wedge and a second opticalwedge. The first optical wedge may be the top wedge and the secondoptical wedge may be the bottom wedge. Through choosing the wedge angle,the energy beams can be made incident on the filament at an angle to theplane of the substrate. By rotating the bottom optical wedge, theincident angle can be varied. By rotating both the optical wedges, theangle of the line beam in the plane of deposition can be varied. Forexample, the first optical wedge may rotate relative to the secondoptical wedge to change the direction of at least the first light beam.The first optical wedge and the second optical wedge can be angled inthe same direction to increase an angle of at least the first energybeam with respect to a reference. The first optical wedge and the secondoptical wedge may rotate in opposite directions to allow the at leastthe first energy beam to pass vertically through the one or more opticalwedges. When altering an angle of incidence of the first optical wedgeand the second optical wedge, or when altering a direction of the majoraxis of at least the first energy beam relative to the substrate or atleast one filament material, the fluence of at least the first lightbeam may be altered. The fluence may be a stream of particles crossing aunit area. The fluence may be expressed as the number of particles persecond. As a result, such light beams may heat at least one filamentmaterial without melting a deposited portion of the at least onefilament material. In some instances, at least the first energy beam canheat and melt a deposited portion of at least one filament material at agiven location among one or more locations.

In some embodiments, at least one filament material may be directed to acompaction unit. Such filament material may be compacted by thecompaction unit to form at least one compacted filament material. Thecompaction unit may comprise a rigid body, one or more idler rollers, atleast one freely suspended roller, a coolant unit, or any combinationthereof. The at least one freely suspended roller may be a compactionroller. The rigid body and one or more idler rollers may secure the atleast one freely suspended roller. Such freely suspended rollers mayhave a diameter of at most about 1 mm, at most about 2 mm, at most about3 mm, at most about 4 mm, at most about 5 mm, at most about 6 mm, atmost about 7 mm, at most about 8 mm, at most about 9 mm, at most about10 mm, or at most about 15 mm. The coolant may be used to cool thecompaction unit so the at least one filament material does not stick tothe roller and adheres only to the previously deposited layer of thethree-dimensional object.

The system for printing at least a portion of the 3D object may furthercomprise one or more cooling components. Such cooling components may bein proximity to the deposited filament material layer. Such coolingcomponents can be located between the deposited filament material layerand the energy source. Such cooling components may be movable to or froma location that may be positioned between the filament material and theenergy source. Such cooling components may assist in the process ofcooling of the fused portion of the filament material layer. Suchcooling components may also assist in the cooling of the filamentmaterial layer remainder that did not fuse to subsequently form at leasta portion of the 3D object. Such cooling components can assist in thecooling of the at least a portion of the 3D object and the remainder atconsiderably the same rate. Such cooling components may be separatedfrom the filament material layer and/or from the substrate by a gap. Thegap may comprise a gas. The gap can have a cross-section that is at mostabout 0.1 mm, at most about 0.5 mm, at most about 1 mm, at most about 5mm, or at most about 10 mm. The gap can be adjustable. The controllermay be operatively connected to such cooling components and may be ableto adjust the gap distance from the substrate. Such cooling componentscan track an energy that may be applied to the portion of the filamentmaterial layer by the energy source. Such cooling components maycomprise a heat sink. Such cooling components may be a cooling fan. Thecontroller may be operatively coupled to such cooling components andcontrols the tracing of such cooling components. Such cooling componentsmay include at least one opening though which at least one energy beamfrom the energy source can be directed to the portion of the filamentlayer. The system for printing at least a portion of the 3D object canfurther comprise an additional energy source that provides energy to aremainder of the filament material layer that did not fuse tosubsequently form at least a portion of the 3D object.

During printing of the three-dimensional object, certain parameters maybe critical to printing high quality parts. One or more sensors can beused to measure one or more temperature(s) along at least one filamentmaterial. Such sensors can control intensities, positions, and/or anglesof at least the first energy beam. The one or more sensors may be anoptical pyrometer. Optical pyrometers may be aimed the substrate todetect the temperature of the at least one filament materials as theyare deposited. Optical pyrometers may be aimed at the nip points and oneor more points before and/or after the compaction unit to detect thetemperature of the at least one filament materials as they aredeposited. The temperature may vary from region to region of thefilament material layer. Factors that affect temperature variance caninclude variable heater irradiance, variations in absorptivity of thecomposition, substrate temperature, filament material temperature,unfused filament material temperature, and the use of modifiers andadditives. Accordingly, image and temperature measurement inputs basedupon layer temperature patterns captured by the one or more sensors maybe used. The real time temperature inputs and the sintering model may befactors determining an energy requirement pattern for any one or moresubsequent layers.

Additionally, the system may comprise a real time simulation program, asample as shown in FIG. 4, to provide feedback control of a givenlocation, direction, or angle of at least the first energy beam normalto the substrate and/or along the substrate among one or more locations,directions, or angles. The sample real time simulation of the opticalbeam path illustrates that choosing the appropriate wedge angle andenergy beam orientation may result in the elliptical beam profile inFIG. 4. The real time simulation program may be a feedback controlsystem. The feedback control system may be a Zemax simulation of thebeam propagation.

Other parameters critical to printing high quality parts can includesubstrate temperature, melt zone temperature, as-built geometry, surfaceroughness and texture and density. Other critical visible or non-visiblemetrics include characterization of chemistry, bonding or adhesionstrength. Measuring one or more structural or internal properties of thepart can comprise one or more methods selected from the group consistingof scattered and reflected or absorbed radiation, x-ray imaging, soundwaves, scatterometry techniques, ultrasonic techniques, X-rayPhotoelectron Spectroscopy (XPS), Four Transform Infrared Spectroscopy(FTIR), Raman Spectroscopy, Laser-Microprobe Mass Spectrometry (LMMS),and any combination thereof. Specific metrology beneficial to the endgoals of characterizing the critical process parameters can be used.This in-situ metrology coupled with fast processing of data can enableopen or closed loop control of the manufacturing process. Sensorsappropriate to the key parameters of interest can be selected andutilized during the part printing process. The sensors may also comprisea camera for detecting light in the infrared or visible portion of theelectromagnetic spectrum. Sensors such as IR cameras may be used tomeasure temperature fields. An image processing algorithm may be used toevaluate data generated by one or more sensors, to extract one or morestructural or internal properties of the part. Visual (e.g., highmagnification) microscopy from digital camera(s) can be used with propersoftware processing to detect voids, defects, and surface roughness. Inorder to utilize this technique, potentially large quantities of datamay need to be interrogated using image processing algorithms in orderto extract features of interest. Scatterometry techniques may be adaptedto provide roughness or other data.

Ultrasonic techniques can be used to measure solid density and fiber andparticle density which in turn may be useful in characterizing bondstrength and fiber dispersion. The characterization can affect materialstrength. Ultrasonic techniques can also be used to measure thickness offeatures. Chemical bonding characterization, which may be useful forunderstanding fiber and/or matrix adhesion and layer-to-layer bonding,can be performed by multiple techniques such as XPS (X-ray PhotoelectronSpectroscopy), FTIR (Four Transform Infrared Spectroscopy) and RamanSpectroscopy and Laser-Microprobe Mass Spectrometry (LMMS). One or moreof these techniques may be utilized as part of the in-situ metrology for3D printing. Ex-situ techniques may also be utilized in order to helpprovide appropriate calibration data for the in-situ techniques.

Sensors may be positioned on the robot end-effector of thethree-dimensional printer in order to provide a sensor moving along withthe deposited material. A robot end-effector may be a device positionedat the end of a robotic arm. The robot end-effector may be programmed tointeract with its surrounding environment. Sensors may be also locatedat other various positions. The positions can be on-board the robot, onthe effector, or deployed in the environment. Sensors may be incommunication with the system. The system can further comprise one ormore processors, a communication unit, memory, power supply, andstorage. The communications unit can comprise an input and an output.The communication unit can be wired or wireless. The sensor measurementsmay or may not be stored in a database, and may or may not be used infuture simulation and optimization operations. In-situ measurements mayalso be made using alternative methods with sensors in a cell but notdirectly attached to the robot end-effector.

In another aspect, the present disclosure provides for method forprinting at least a portion of a three-dimensional (3D) object. At leastone filament material may be directed from a source of at least onefilament material towards a substrate that is configured to support the3D object, thereby depositing a first layer corresponding to a portionof the 3D object adjacent to the substrate, which first layer isdeposited in accordance with the model of the 3D object. At least onefilament material from the source may be deposited to an opening. Suchfilament material may then be directed from the opening towards thesubstrate. At least a first energy beam from at least one energy sourcemay be used to melt at least a portion of the first layer. A secondlayer of at least a portion of the 3D object may be deposited, whichsecond layer is deposited in accordance with the model of the 3D object,thereby generating at least a portion of the 3D object. In someembodiments, such method may be repeated one or more times. Prior todirecting at least one filament material from a source of the at leastone filament material towards a substrate that is configured to supportthe 3D object, thereby depositing a first layer corresponding to aportion of the 3D object adjacent to the substrate, a model of the 3Dobject may be received in computer memory. In some cases, fuseddeposition modeling may be performed when printing the 3D object. Inother cases, the 3D object may be printed with extrusion. In some cases,the 3D object may be printed without extrusion.

The layered structure can comprise substantially repetitive layers. Thelayers may have an average layer size of at least about 0.5 μm, 1 μm, 5μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, 450 μm, 500 μm, 1mm, 25 mm, 50 mm, 100 mm, 500 mm, or 1 m. The layers may have an averagelayer size of at most about 50 m, 1 m, 500 mm, 100 mm, 50 mm, 2.5 mm, 1mm, 500 μm, 450 μm, 400 μm, 350 μm, 300 μm, 250 μm, 200 μm, 150 μm, 100μm, 90 μm, 80 μm, 70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 2.0 μm, or 10 μm.The layers may have an average layer size of any value between theaforementioned values of layer size. For example, the layers may have anaverage layer size from about 0.5 μm to about 500 mm, from about 15 μmto about 100 μm, from about 5 μm to about 300 μm, from about 20 μm toabout 90 μm, or from about 10 μm to about 70 μm. The layered structurecan be indicative of layered deposition. The layered structure can beindicative of solidification of melt pools formed during a threedimensional printing process. The structure indicative of a threedimensional printing process can comprise substantially repetitivevariation comprising: variation in grain orientation, variation inmaterial density, variation in the degree of compound segregation tograin boundaries, variation in the degree of element segregation tograin boundaries, variation in material phase, variation inmetallurgical phase, variation in material porosity, variation incrystal phase, or variation in crystal structure. The melt pools may beindicative of an additive manufacturing process comprisingstereolithography (SLA), selective laser melting (SLM), selective lasersintering (SLS), digital light processing (DLP), electron beam melting(EBM), laminated object manufacturing (LOM), binder jetting (BM),material jetting/wax casting (MJ), direct metal laser sintering (DMLS),or fused deposition modeling (FDM). The melt pools may be indicative ofan additive manufacturing process comprising selective energy melting.

The source of at least one filament material may be configured to supplyat least one filament material for generating the three-dimensionalobject. The at least one filament material may be a composite material,such as a continuous fiber composite. The filament material may be nanomilled, short, long, continuous, or a combination thereof. Thecontinuous fiber composite may be a continuous core reinforced filament.The continuous core reinforced filament can comprise a towpreg that issubstantially void free and includes a polymer that coats or impregnatesan internal continuous core. Depending upon the particular embodiment,the core may be a solid core or it may be a multi-strand core comprisingmultiple strands. The continuous fiber composite may be selected fromthe group consisting of glass, carbon, aramid, cotton, silicon carbide,polymer, wool, metal, and any combination thereof.

The filament material may incorporate one or more additional materials,such as resins and polymers. For example, appropriate resins andpolymers include, but are not limited to, acrylonitrile butadienestyrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI),Polyaryletherketone (PAEK), Polyether ether ketone (PEEK), PolyacticAcid (PLA), Liquid Crystal Polymer, polyamide, polyimide, polyphenylenesulfide, polyphenylsulfone, polysulfone, polyether sulfone,polyethylenimine, polytetrafluoroethylene, polyvinylidene, and variousother thermoplastics. The core of the continuous fiber composite may beselected to provide any desired property. Appropriate core fiber orstrands include those materials which impart a desired property, such asstructural, conductive (electrically and/or thermally), insulative(electrically and/or thermally), optical and/or fluidic transport. Suchmaterials include, but are not limited to, carbon fibers, aramid fibers,fiberglass, metals (such as copper, silver, gold, tin, and steel),optical fibers, and flexible tubes. The core fiber or strands may beprovided in any appropriate size. Further, multiple types of continuouscores may be used in a single continuous core reinforced filament toprovide multiple functionalities such as electrical and opticalproperties. A single material may be used to provide multiple propertiesfor the core reinforced filament. For example, a steel core may be usedto provide both structural properties as well as electrical conductivityproperties.

Alternatively, the filament material may comprise metal particlesinfused into a binder matrix. The metal particles may be metal powder.The binder matrix may include resins or polymers. Additionally, suchbinder matrix can be used a delivery device for the metal particles.Once the filament material is deposited onto the base, one or moreenergy sources can heat and melt the binder matrix, leaving the metalparticles to melt and fuse into larger metal particles. Such energysources may be without limitation, by a laser, a microwave source, aresistive heating source, an infrared energy source, a UV energy source,a hot fluid, a chemical reaction, a plasma source, a microwave source,an electromagnetic source, or an electron beam. Resistive heating may bejoule heating. A source for resistive heating may be a power supply. Theat least one filament material may be a metal filament. The at least onefilament material may be a metal filament composite. The deposited atleast one filament material may be subjected to resistive heating uponflow of an electrical current through the at least one filamentmaterial. The resistive heating may be sufficient to melt at least aportion of the deposited at least one filament material. The at leastone filament material may be an electrode. The substrate may be anotherelectrode.

The one or more energy sources may also provide localized heating tocreate a “melt pool” in the current layer or segment of the depositedbuild material prior to depositing the next segment or layer. The meltpool can increase diffusion and mixing of the build material betweenadjacent layers (e.g., across a direction orthogonal to the layers) ascompared to other methods which deposit a subsequent layer of buildmaterial on top of a layer of build material that is below its meltingtemperature.

The increased diffusion and mixing resulting from the melt pool mayincrease the chemical chain linkage, bonding, and chemical chaininteractions between the two layers. This can result in increasing thebuild-material adhesion in the Z direction, thereby enhancingmechanical, thermal, and electrical properties of the three-dimensionalobject. The melt pool can also reduce the void space and porosity in thebuild object. Among other benefits, this decrease in porosity may alsocontribute to the aforementioned improvement in mechanical, thermal, andelectrical properties.

The at least one filament material may have a cross sectional shapeselected from the group consisting of circle, ellipse, parabola,hyperbola, convex polygon, concave polygon, cyclic polygon, equilateralpolygon, equiangular polygon, regular convex polygon, regular starpolygon, tape-like geometry, and any combination thereof. Such filamentmaterial can have a diameter of at most about 0.1 millimeters (mm), atmost about 0.2 mm, at most about 0.3 mm, at most about 0.4 mm, at mostabout 0.5 mm, at most about 0.6 mm, at most about 0.7 mm, at most about0.8 mm, at most about 0.9 mm, at most about 1 mm, at most about 2 mm, atmost about 3 mm, at most about 4 mm, at most about 5 mm, at most about10 mm, or at most about 20 mm.

Various modifiers within the layers themselves may be used which areselectively printed onto specific regions of the 3D object in order toimpart various desirable mechanical, chemical, magnetic, electrical orother properties to the 3D object, Such modifiers may be selected fromthe group consisting of thermal conductors and insulators, dielectricpromoters, electrical conductors and insulators, locally-containedheater traces for multi-zone temperature control, batteries, andsensors. In some embodiments, at least one print head can be may be usedfor printing such modifiers. As desired, such modifiers can be printedbefore at least a first energy beam is directed onto at least a portionof the first layer and/or second layer. Alternatively, such modifiersmay be printed over a layer that has been melted, before filamentmaterial for the next layer is deposited.

For example, when printing a polyimide part from commercially availablea filament comprising polyimide, an array of electrically conductivetraces may be assimilated as an antenna to selectively absorbradiofrequency (RF) radiation within a specific and predeterminedfrequency range. The 3D object CAD model and software can designate as asub-part the layer(s) that comprise the traces for modified properties(high electrical conductivity). Alternatively, if these portions of thelayer entail different levels of energy for inducing fusion, compared toother regions having only the primary material, the CAD model and designof the 3D object may be adjusted accordingly.

After deposition of a first layer and/or a second layer of at least aportion of the 3D object, and before fusion is induced, the filamentmaterial may be preheated to a temperature sufficient to reduceundesirable shrinkage and/or to minimize the laser energy needed to meltthe next layer. For example, the preheating may be accomplished usingthe infrared heater attached to substrate or through other apparatusesof directing thermal energy within an enclosed space around thesubstrate. Alternatively, the preheating can be accomplished usingenergy beam melting by defocusing the energy beam and rapidly scanningit over the deposited first layer and or second layer of at least aportion of the 3D object.

In some embodiments, at least a first energy beam from at least oneenergy source may be used to selectively heat and/or melt at least aportion of the first layer and/or the second layer, thereby forming atleast a portion of the 3D object. The energy source may be selected fromthe group consisting of a laser, a microwave source, a resistive heatingsource, an infrared energy source, a UV energy source, a hot fluid, achemical reaction, a plasma source, a microwave source, anelectromagnetic source, an electron beam, or any combination thereof.Resistive heating may be joule heating. A source for resistive heatingmay be a power supply. The at least one filament material may be a metalfilament. The at least one filament material may be a metal filamentcomposite. The deposited at least one filament material may be subjectedto resistive heating upon flow of an electrical current through the atleast one filament material. The resistive heating may be sufficient tomelt at least a portion of the deposited at least one filament material.The at least one filament material may be an electrode. The substratemay be another electrode.

The energy source may be a function of the chemical composition of thebuild material, such as the build material's thermal conductivity, heatcapacity, latent heat of fusion, melting point, and melt flow viscosity.The at least one energy source may be a laser. The laser may be selectedfrom the group consisting of gas lasers, chemical lasers, dye lasers,metal-vapor lasers, solid-state lasers, semiconductor lasers, freeelectron laser, gas dynamic laser, nickel-like samarium laser, Ramanlaser, nuclear pump laser, and any combination thereof. Gas lasers maycomprise one or more of helium-neon laser, argon laser, krypton laser,xenon ion laser, nitrogen laser, carbon dioxide laser, carbon monoxidelaser, and excimer laser. Chemical lasers may be selected from the groupconsisting of hydrogen fluoride laser, deuterium fluoride laser,chemical oxygen-iodine laser, all gas-phase iodine laser, and anycombination thereof. Metal-vapor lasers can comprise one or more ofhelium-cadmium, helium mercury, helium selenium, helium silver,strontium vapor laser, neon-copper, copper vapor laser, gold vaporlaser, and manganese vapor laser. Solid-state lasers may be selectedfrom the group consisting of ruby laser, neodymium-doped yttriumaluminium garnet laser, neodymium and chromium-doped yttrium aluminiumgarnet laser, erbium-doped yttrium aluminium garnet laser,neodymium-doped yttrium lithium fluoride laser, neodymium doped yttriumothovanadate laser, neodymium doped yttrium calcium oxoborate laser,neodymium glass laser, titanium sapphire laser, thulium yttriumaluminium garnet laser, ytterbium yttrium aluminium garnet laser,ytterbium:₂O₃ (glass or ceramics) laser, ytterbium doped glass laser(rod, plate/chip, and fiber), holmium yttrium aluminium garnet laser,chromium zinc selenium laser, cerium doped lithium strontium (orcalcium) aluminum fluoride laser, Promethium 147 doped phosphate glasssolid-state laser, chromium doped chrysoberyl (alexandrite) laser,erbium doped and erbium-ytterbium codoped glass lasers, trivalenturanium doped calcium fluoride solid-state laser, divalent samariumdoped calcium fluoride laser, FARBE center laser, and any combinationthereof. Semiconductor laser may comprise one or more of semiconductorlaser diode laser, gallium nitride laser, indium gallium nitride laser,aluminium gallium indium phosphide laser, aluminium gallium arsenidelaser, indium gallium arsenide phosphide laser, lead salt laser,vertical cavity surface emitting laser, quantum cascade laser, andhybrid silicon laser.

The melting temperature of the at least one filament material can be atleast about 150° C., at least about 200° C., at least about 250° C., atleast about 300° C., at least about 350° C., at least about 400° C., atleast about 450° C. The sintering temperature can be at most about 150°C., at most about 200° C., at most about 250° C., at most about 300° C.,at most about 350° C., at most about 400° C. The method may furthercomprise separating the remainder of the layer that did not fuse andsolidify to form at least a portion of the three dimensional object,from the portion.

The at least one energy beam from the energy source may be directed tothe at least one portion of the 3D object adjacent to the substrate.Such energy beams may be sufficient to induce fusion of particles of thefilament material within the desired cross-sectional geometry of the atleast one portion of the 3D object. As the energy dissipates withcooling, atoms from neighboring particles may fuse together. In someembodiments, the at least one energy beam results in the fusion ofparticles of filament material both within the same layer and in thepreviously formed and resolidified adjoining layer(s) such that fusionis induced between at least two adjacent layers of the part, such asbetween at least one filament material in a deposited unfused layer anda previously-fused adjacent layer. This process is then repeated overmultiple cycles as each part layer is added, until the full 3D object isformed.

In some cases, to create a melt pool large enough to span the width ofthe filament material segment, multiple energy sources or a combinationof energy sources may be required. When multiple energy sources areused, the energy sources may be the same energy source. Alternatively,the multiple energy sources may be different energy sources. The energysource(s) may be separate from the system for printing at least aportion of the 3D object. In other embodiments, the energy source(s) maybe integrated with such system. For example, in one embodiment, a hotfluid (e.g., hot air) may be channeled through the deposition nozzle.Because the material filament can flow in the melt pool, features of the3D object being built can be altered. In some embodiments, the melt poolmay be formed within the build object, such that a melt pool is notformed near the perimeters thereof. To accomplish this, the energysource may be turned off when the perimeters of the object are beingbuilt. In such embodiments, the geometrical tolerance of the buildobject may be maintained while the interior of the object has enhancedinterlayer bonding. During printing, the filament material may beprinted in the X, Y, and Z directions in one segment or layer.

The at least one energy source may be in optical communication with oneor more beam splitters, which one or more beam splitters can split anenergy beam from at least one light source into one or more beamletsthat yields at least the first energy beam. The example optical systemin FIG. 3 may be capable of receiving in an opening 301, splitting, anddirecting such energy beams at various angles to the plane of thesubstrate 208 of system 200. System 300 can comprise one or more beamsplitters 302, one or more focusing lenses 303, one or more opticalwedges 304, and any combination thereof. The optical system 300 mayallow the energy beams to be aligned at any angle in the plane ofdeposition. The optical system may further comprise a beam expandingsystem and a spatial light modulator. At least the first energy beam maybe emitted by at least one light source and expanded by the beamexpanding system into parallel light beams having a large diameter bythe beam expanding system. Then, such parallel energy beams mayirradiate onto the one or more beam splitters. A part of the expandedenergy beams may reach a spatial modulator for modulation after passingthrough the beam splitter and the modulated energy beams can bereflected to the beam splitter. A part of the modulated energy beam maybe focused by the focusing system, angled by the optical wedges, andirradiated along the at least one filament material forthree-dimensional printing. The beam expanding system may comprise anegative lens and a positive lens. Furthermore, the spatial lightmodulator can be a reflector type digital micro-mirror device or a phasetype liquid crystal spatial light modulator.

One or more beam splitters may be selected from the group consisting ofprism, glass sheet, plastic sheet, mirror, dielectric mirror,metal-coated mirror, partially reflecting mirror, pellicles, micro-opticbeam splitters, waveguide beam splitters, beam splitter cubes,fiber-optic beam splitter, and any combination thereof. One or moreoptical wedges may be in optical communication with one or more beamsplitters, which one or more optical wedges form at least the firstlight beam. Such optical wedges can form at least the first light beamin a uniform orientation. The one or more beamlets may pass through oneor more focusing lenses prior to passing through at least one or moreoptical wedges. Such beamlets may have an elliptical polarization. Theone or more beamlets may comprise a minor axis of at least about 0.5 mm,at least about 1 mm, at least about 2 mm, at least about 3 mm, at leastabout 4 mm, at least about 5 mm, at least about 6 mm, at least about 7mm, at least about 8 mm, at least about 9 mm, at least about 10 mm, orat least about 15 mm. The one or more beamlets may also comprise a majoraxis of at least about 5 mm, at least about 10 mm, at least about 15 mm,at least about 20 mm, at least about 25 mm, at least about 30 mm, atleast about 35 mm, at least about 40 mm, at least about 45 mm, or atleast about 50 mm. Such energy beams can cover at least a portion of atleast one filament material. The one or more focusing lenses may be usedto adjust a ratio of the minor axis to the major axis of the one or morebeamlets.

Optical wedges may alter the path of the beam from vertical to any anglefor uniform heating of the filament material. The one or more opticalwedges can also direct an optical path of at least the first light beamof a given location, direction, or angle normal to the substrate and/oralong the substrate among one or more locations, directions, or angles.Such a direction of one or more optical wedges can allow for control ofthe heat from the light beam along the at least one filament material.

The one or more optical wedges can be used in combination with one ormore of dispersive prism, reflective prism, beam-splitting prism,polarizing prism, or deflecting prisms. Dispersive prisms may be used tobreak up light into its constituent spectral colors because therefractive index depends on frequency. Examples of dispersive prismsinclude Triangular prism, Abbe prism, Pellin-Broca prism, Amici prism,Compound prism, or Grism prism. Reflective prisms can be used to reflectlight, in order to flip, invert, rotate, deviate or displace the lightbeam. Examples of reflective prisms include Porro prism, Porro-Abbeprism, Amici roof prism, Pentaprism, Roof Pentaprism, Abbe-Koenig prism,Schmidt-Pechan prism, Bauernfeind prism, Dove prism, or Retroreflectorprism. Some reflective prisms may be used for splitting a beam into twoor more beams. Beam-splitting prisms may be a beam splitter cube or adichronic prism. Polarizing prisms can split a beam of light intocomponents of varying polarization. Examples of polarizing prisms may beNicol prism, Wollaston prism, Nomarski prism, Rochon prism, Senarmontprism, Glan-Foucault prism, Glan-Taylor prism, or Glan-Thompson prism.Deflecting prisms may be one or more of a Risley prism pair, Rhomboidprisms, or Deck prisms. Wedge prisms may be used to deflect a beam oflight by a fixed angle. A pair of such prisms can be used for beamsteering; by rotating the prisms the beam can be deflected into anydesired angle. The deflecting prism may be a Risley prism pair. Twowedge prisms can also be used as an anamorphic pair to change the shapeof a beam. For example, this may be used to generate a round beam fromthe elliptical output of a laser diode.

One or more optical wedges can have a refractive index of at least about0.5, at least about 1, at least about 1.1, at least about 1.2, at leastabout 1.3, at least about 1.4, at least about 1.5, at least about 1.6,at least about 1.7, at least about 1.8, at least about 1.9, at leastabout 2.5, at least about 3, at least about 4, or at least about 5. Suchoptical wedges can have a diameter of at most about 0.1 inches (in), atmost about 0.2 in, at most about 0.3 in, at most about 0.4 in, at mostabout 0.5 in, at most about 0.6 in, at most about 0.7 in, at most about0.8 in, at most about 0.9 in, at most about 1 in, at most about 2 in, atmost about 3 in, at most about 4 in, or at most about 5 in.

In some embodiments, at least the first energy beam may be incident onat least one filament material and on the substrate. Such energy beamsmay be directed along a given angle among one or more angles relative tothe dispensing route of at least one filament material. The one or moreoptical wedges can comprise a first optical wedge and a second opticalwedge. The first optical wedge may be the top wedge and the secondoptical wedge may be the bottom wedge. Through choosing the wedge angle,the energy beams can be made incident on the filament at an angle to theplane of the substrate. By rotating the bottom optical wedge, theincident angle can be varied. By rotating both the optical wedges, theangle of the line beam in the plane of deposition can be varied. Forexample, the first optical wedge may rotate relative to the secondoptical wedge to change the direction of at least the first light beam.The first optical wedge and the second optical wedge can be angled inthe same direction to increase an angle of at least the first energybeam with respect to a reference. The energy beam may be a light beam.The first optical wedge and the second optical wedge may rotate inopposite directions to allow the at least the first energy beam to passvertically through the one or more optical wedges. When altering anangle of incidence of the first optical wedge and the second opticalwedge, or when altering a direction of the major axis of at least thefirst energy beam relative to the substrate or at least one filamentmaterial, the fluence of at least the first light beam may be altered.As a result, such light beams may heat at least one filament materialwithout melting a deposited portion of the at least one filamentmaterial. In some instances, at least the first energy beam can heat andmelt a deposited portion of at least one filament material at a givenlocation among one or more locations.

In some embodiments, at least one filament material may be directed to acompaction unit. Such filament material may be compacted by such acompaction unit to form at least one compacted filament material. Thecompaction unit may comprise a rigid body, one or more idler rollers, atleast one freely suspended roller, a coolant unit, or any combinationthereof. The at least one freely suspended roller may be a compactionroller. The rigid body and one or more idler rollers may secure the atleast one freely suspended roller. Such freely suspended rollers mayhave a diameter of at most about 1 mm, at most about 2 mm, at most about3 mm, at most about 4 mm, at most about 5 mm, at most about 6 mm, atmost about 7 mm, at most about 8 mm, at most about 9 mm, at most about10 mm, or at most about 15 mm. The coolant may be used to cool thecompaction unit so the at least one filament material does not stick tothe roller and adheres only to the previously deposited layer of thethree-dimensional object.

The system for printing at least a portion of the 3D object may furthercomprise one or more cooling components. Such cooling components may bein proximity to the deposited filament material layer. Such coolingcomponents can be located between the deposited filament material layerand the energy source. Such cooling components may be movable to or froma location that may be positioned between the filament material and theenergy source. Such cooling components may assist in the process ofcooling of the fused portion of the filament material layer. Suchcooling components may also assist in the cooling of the filamentmaterial layer remainder that did not fuse to subsequently form at leasta portion of the 3D object. Such cooling components can assist in thecooling of the at least a portion of the 3D object and the remainder atconsiderably the same rate. Such cooling components may be separatedfrom the filament material layer and/or from the substrate by a gap. Thegap may comprise a gas. The gap can have a cross-section that is at mostabout 0.1 mm, at most about 0.5 mm, at most about 1 mm, at most about 5mm, or at most about 10 mm. The gap can be adjustable. The controllermay be operatively connected to such cooling components and may be ableto adjust the gap distance from the substrate. Such cooling componentscan track an energy that may be applied to the portion of the filamentmaterial layer by the energy source. Such cooling components maycomprise a heat sink. Such cooling components may be a cooling fan. Thecontroller may be operatively coupled to such cooling components andcontrols the tracing of such cooling components. Such cooling componentsmay include at least one opening though which at least one energy beamfrom the energy source can be directed to the portion of the filamentlayer. The system for printing at least a portion of the 3D object canfurther comprise an additional energy source that provides energy to aremainder of the filament material layer that did not fuse tosubsequently form at least a portion of the 3D object.

During printing of the three-dimensional object, certain parameters maybe critical to printing high quality parts. One or more sensors can beused to measure one or more temperature(s) along at least one filamentmaterial. Such sensors can control intensities, positions, and/or anglesof at least the first energy beam. The one or more sensors may be anoptical pyrometer. Optical pyrometers may be aimed the substrate todetect the temperature of the at least one filament materials as theyare deposited. Optical pyrometers may be aimed at the nip points and oneor more points before and/or after the compaction unit to detect thetemperature of the at least one filament materials as they aredeposited. The temperature may vary from region to region of thefilament material layer. Factors that affect temperature variance caninclude variable heater irradiance, variations in absorptivity of thecomposition, substrate temperature, filament material temperature,unfused filament material temperature, and the use of modifiers andadditives. Accordingly, image and temperature measurement inputs basedupon layer temperature patterns captured by the one or more sensors maybe used. The real time temperature inputs and the sintering model may befactors determining an energy requirement pattern for any one or moresubsequent layers.

Additionally, the system may comprise a real time simulation program, asample as shown in FIG. 4, to provide feedback control of a givenlocation, direction, or angle of at least the first energy beam normalto the substrate and/or along the substrate among one or more locations,directions, or angles. The sample real time simulation of the opticalbeam path illustrates that choosing the appropriate wedge angle andenergy beam orientation may result in the elliptical beam profile inFIG. 4. The real time simulation program may be a feedback controlsystem. The feedback control system may be a Zemax simulation of thebeam propagation.

Other parameters critical to printing high quality parts can includesubstrate temperature, melt zone temperature, as-built geometry, surfaceroughness and texture and density. Other critical visible or non-visiblemetrics include characterization of chemistry, bonding or adhesionstrength. Measuring one or more structural or internal properties of thepart can comprise one or more methods selected from the group consistingof scattered and reflected or absorbed radiation, x-ray imaging, soundwaves, scatterometry techniques, ultrasonic techniques, X-rayPhotoelectron Spectroscopy (XPS), Four Transform Infrared Spectroscopy(FTIR), Raman Spectroscopy, Laser-Microprobe Mass Spectrometry (LMMS),and any combination thereof. Specific metrology beneficial to the endgoals of characterizing the critical process parameters can be used.This in-situ metrology coupled with fast processing of data can enableopen or closed loop control of the manufacturing process. Sensorsappropriate to the key parameters of interest can be selected andutilized during the part printing process. The sensors may also comprisea camera for detecting light in the infrared or visible portion of theelectromagnetic spectrum. Sensors such as IR cameras may be used tomeasure temperature fields. An image processing algorithm may be used toevaluate data generated by one or more sensors, to extract one or morestructural or internal properties of the part. Visual (e.g., highmagnification) microscopy from digital camera(s) can be used with propersoftware processing to detect voids, defects, and surface roughness. Inorder to utilize this technique, potentially large quantities of datamay need to be interrogated using image processing algorithms in orderto extract features of interest. Scatterometry techniques may be adaptedto provide roughness or other data.

Ultrasonic techniques can be used to measure solid density and fiber andparticle density which in turn may be useful in characterizing bondstrength and fiber dispersion. The characterization can affect materialstrength. Ultrasonic techniques can also be used to measure thickness offeatures. Chemical bonding characterization, which may be useful forunderstanding fiber and/or matrix adhesion and layer-to-layer bonding,can be performed by multiple techniques such as XPS (X-ray PhotoelectronSpectroscopy), FTIR (Four Transform Infrared Spectroscopy) and RamanSpectroscopy and Laser-Microprobe Mass Spectrometry (LMMS). One or moreof these techniques may be utilized as part of the in-situ metrology for3D printing. Ex-situ techniques may also be utilized in order to helpprovide appropriate calibration data for the in-situ techniques.

Sensors may be positioned on the robot end-effector of thethree-dimensional printer in order to provide a sensor moving along withthe deposited material. A robot end-effector may be a device positionedat the end of a robotic arm. The robot end-effector may be programmed tointeract with its surrounding environment. Sensors may be also locatedat other various positions. The positions can be on-board the robot, onthe effector, or deployed in the environment. Sensors may be incommunication with the system. The system can further comprise one ormore processors, a communication unit, memory, power supply, andstorage. The communications unit can comprise an input and an output.The communication unit can be wired or wireless. The sensor measurementsmay or may not be stored in a database, and may or may not be used infuture simulation and optimization operations. In-situ measurements mayalso be made using alternative methods with sensors in a cell but notdirectly attached to the robot end-effector.

In another aspect, the present disclosure provides a system for printingat least a portion of a three-dimensional (3D) object. The system maycomprise a source of at least one filament material that is configuredto supply at least one filament material for generating the 3D object.The system may comprise a substrate for supporting at least a portion ofthe 3D object. The system may additionally comprise at least one energysource configured to deliver at least a first energy beam. The systemcan comprise a controller operatively coupled to the at least one energysource, wherein the controller is programmed to (i) receive, in computermemory, a model of the 3D object, (ii) subsequent to receiving the modelof the 3D object, direct the at least one filament material from thesource of the at least one filament material towards the substrate thatis configured to support the 3D object, thereby depositing a first layercorresponding to a portion of the 3D object adjacent to the substrate,which first layer is deposited in accordance with the model of the 3Dobject, (iii) deposit a second layer corresponding to at least a portionof the 3D object, which second layer is deposited in accordance with themodel of the 3D object, and (iv) use at least a first energy beam fromat least one energy source to selectively melt at least a portion of thefirst layer and/or the second layer, thereby forming at least a portionof the 3D object.

In some cases, the controller may be programmed to perform fuseddeposition modeling when printing the 3D object. In other cases, thecontroller may be programmed to print the 3D object with extrusion. Insome cases, the controller may be programmed to print the 3D objectwithout extrusion. The controller can be further programmed to depositone or more additional layers adjacent to the first layer prior todepositing the second layer. The system may further comprise an openingfor (i) receiving at least one filament material, and (ii) directing atleast one filament material towards the substrate.

The layered structure can comprise substantially repetitive layers. Thelayers may have an average layer size of at least about 0.01 μm, 0.1 μm,0.5 μm, 1 μm, 5 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80μm, 90 μm, 100 μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, 450μm, 500 m, 1 mm, 25 mm, 50 mm, 100 mm, 500 mm, or 1 m. The layers mayhave an average layer size of at most about 50 m, 1 m, 500 mm, 100 mm,50 mm, 25 mm, 1 mm, 500 μm, 450 μm, 400 μm, 350 μm, 300 μm, 250 μm, 200μm, 150 μm, 100 μm, 90 μm, 80 μm, 70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 20μm, or 10 μm. The layers may have an average layer size of any valuebetween the aforementioned values of layer size. For example, the layersmay have an average layer size from about 0.5 μm to about 500 mm, fromabout 15 μm to about 100 μm, from about 5 μm to about 300 μm, from about20 μm to about 90 μm, or from about 10 μm to about 70 μm. The layeredstructure can be indicative of layered deposition. The layered structurecan be indicative of solidification of melt pools formed during a threedimensional printing process. The structure indicative of a threedimensional printing process can comprise substantially repetitivevariation comprising: variation in grain orientation, variation inmaterial density, variation in the degree of compound segregation tograin boundaries, variation in the degree of element segregation tograin boundaries, variation in material phase, variation inmetallurgical phase, variation in material porosity, variation incrystal phase, or variation in crystal structure. The melt pools may beindicative of an additive manufacturing process comprisingstereolithography (SLA), selective laser melting (SLM), selective lasersintering (SLS), digital light processing (DLP), electron beam melting(EBM), laminated object manufacturing (LOM), binder jetting (BM),material jetting/wax casting (MJ), direct metal laser sintering (DMLS),or fused deposition modeling (FDM). The melt pools may be indicative ofan additive manufacturing process comprising selective energy melting.

The source of at least one filament material may be configured to supplyat least one filament material for generating the three-dimensionalobject. The at least one filament material may be stored on one or morespools or cartridges. The spools and/or cartridges may be replaceable.The at least one filament material may be a composite material, such asa continuous fiber composite. The filament material may be nano milled,short, long, continuous, or a combination thereof. The continuous fibercomposite may be a continuous core reinforced filament. The continuouscore reinforced filament can comprise a towpreg that is substantiallyvoid free and includes a polymer that coats or impregnates an internalcontinuous core. Depending upon the particular embodiment, the core maybe a solid core or it may be a multi-strand core comprising multiplestrands. The continuous fiber composite may be selected from the groupconsisting of glass, carbon, aramid, cotton, silicon carbide, polymer,wool, metal, and any combination thereof.

The filament material may incorporate one or more additional materials,such as resins and polymers. For example, appropriate resins andpolymers include, but are not limited to, acrylonitrile butadienestyrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI),Polyaryletherketone (PAEK), Polyether ether ketone (PEEK), PolyacticAcid (PLA), Liquid Crystal Polymer, polyamide, polyimide, polyphenylenesulfide, polyphenylsulfone, polysulfone, polyether sulfone,polyethylenimine, polytetrafluoroethylene, polyvinylidene, and variousother thermoplastics. The core of the continuous fiber composite may beselected to provide any desired property. Appropriate core fiber orstrands include those materials which impart a desired property, such asstructural, conductive (electrically and/or thermally), insulative(electrically and/or thermally), optical and/or fluidic transport. Suchmaterials include, but are not limited to, carbon fibers, aramid fibers,fiberglass, metals (such as copper, silver, gold, tin, and steel),optical fibers, and flexible tubes. The core fiber or strands may beprovided in any appropriate size. Further, multiple types of continuouscores may be used in a single continuous core reinforced filament toprovide multiple functionalities such as electrical and opticalproperties. A single material may be used to provide multiple propertiesfor the core reinforced filament. For example, a steel core may be usedto provide both structural properties as well as electrical conductivityproperties.

Alternatively, the filament material may comprise metal particlesinfused into a binder matrix. The metal particles may be metal powder.The binder matrix may include resins or polymers. Additionally, suchbinder matrix can be used a delivery device for the metal particles.Once the filament material is deposited onto the base, one or moreenergy sources can heat and melt the binder matrix, leaving the metalparticles to melt and fuse into larger metal particles. Such energysources may be without limitation, by a laser, a microwave source, aresistive heating source, an infrared energy source, a UV energy source,a hot fluid, a chemical reaction, a plasma source, a microwave source,an electromagnetic source, or an electron beam. Resistive heating may bejoule heating. A source for resistive heating may be a power supply. Theat least one filament material may be a metal filament. The at least onefilament material may be a metal filament composite. The deposited atleast one filament material may be subjected to resistive heating uponflow of an electrical current through the at least one filamentmaterial. The resistive heating may be sufficient to melt at least aportion of the deposited at least one filament material. The at leastone filament material may be an electrode. The substrate may be anotherelectrode.

The one or more energy sources may also provide localized heating tocreate a “melt pool” in the current layer or segment of the depositedbuild material prior to depositing the next segment or layer. The meltpool can increase diffusion and mixing of the build material betweenadjacent layers (e.g., across a direction orthogonal to the layers) ascompared to other methods which deposit a subsequent layer of buildmaterial on top of a layer of build material that is below its meltingtemperature.

The hot fluid can have a temperature greater than 25° C., or greaterthan or equal to about 40° C., 50° C., 60° C., 70° C., 80° C., 90° C.,100° C., 150° C., 200° C., 250° C., 300° C., 350° C., 400° C., 450° C.,500° C., or higher. The hot fluid may have a temperature that isselected to soften or melt a material used to print an object. The hotfluid may have a temperature that is at or above a melting point orglass transition point of a polymeric material. The hot fluid can be agas or a liquid. In some examples, the hot fluid is air.

The increased diffusion and mixing resulting from the melt pool mayincrease the chemical chain linkage, bonding, and chemical chaininteractions between the two layers. This can result in increasing thebuild-material adhesion in the Z direction, thereby enhancingmechanical, thermal, and electrical properties of the three-dimensionalobject. The melt pool can also reduce the void space and porosity in thebuild object. Among other benefits, this decrease in porosity may alsocontribute to the aforementioned improvement in mechanical, thermal, andelectrical properties.

The at least one filament material may have a cross sectional shapeselected from the group consisting of circle, ellipse, parabola,hyperbola, convex polygon, concave polygon, cyclic polygon, equilateralpolygon, equiangular polygon, regular convex polygon, regular starpolygon, tape-like geometry, and any combination thereof. Such filamentmaterial can have a diameter of at most about 0.1 millimeters (mm), atmost about 0.2 mm, at most about 0.3 mm, at most about 0.4 mm, at mostabout 0.5 mm, at most about 0.6 mm, at most about 0.7 mm, at most about0.8 mm, at most about 0.9 mm, at most about 1 mm, at most about 2 mm, atmost about 3 mm, at most about 4 mm, at most about 5 mm, at most about10 mm, or at most about 20 mm.

Various modifiers within the layers themselves may be used which areselectively printed onto specific regions of the 3D object in order toimpart various desirable mechanical, chemical, magnetic, electrical orother properties to the 3D object. Such modifiers may be selected fromthe group consisting of thermal conductors and insulators, dielectricpromoters, electrical conductors and insulators, locally-containedheater traces for multi-zone temperature control, batteries, andsensors. In some embodiments, at least one print head can be may be usedfor printing such modifiers. As desired, such modifiers can be printedbefore at least a first energy beam is directed onto at least a portionof the first layer and/or second layer. Alternatively, such modifiersmay be printed over a layer that has been melted, before filamentmaterial for the next layer is deposited.

For example, when printing a polyimide part from commercially availablea filament comprising polyimide, an array of electrically conductivetraces may be assimilated as an antenna to selectively absorbradiofrequency (RF) radiation within a specific and predeterminedfrequency range. The 3D object CAD model and software can designate as asub-part the layer(s) that comprise the traces for modified properties(high electrical conductivity). Alternatively, if these portions of thelayer entail different levels of energy for inducing fusion, compared toother regions having only the primary material, the CAD model and designof the 3D object may be adjusted accordingly.

In some embodiments, the system for printing at least a portion of athree-dimensional object may comprise at least one print head. The atleast one print head may comprise one or more dies for extrusion. The atleast one print head also deposit printed material without extrusion.

In some embodiments, the system for printing at least a portion of athree-dimensional object may comprise a build plate form. The system mayalso comprise a substrate. The substrate may be able to withstand hightemperatures. The substrate may have high thermal tolerances, and ableto withstand high temperatures, such as at least about 50° C., at leastabout 100° C., at least about 150° C., at least about 200° C., at leastabout 250° C., at least about 300° C., at least about 350° C., or atleast about 400° C.

The substrate may be a non-removable. The substrate may be a removableplate secured over the build platform. In an embodiment, guidinglegs/rails may be used to slide the removable plate into multiplegrooves and multiple set screws and fasteners to secure the plate ontothe build platform. In another embodiment, the spring/latchquick-release mechanism may be used to secure in place and remove theplate. The method to secure the plate may also be vacuum suction of theplate onto build platform. The method to secure the plate can be magnetsand/or electromagnets.

The substrate may be thermally conductive in nature, so that it can beheated. The substrate can be heated from the heated build platform bythe temperature control components, such as heater cartridges. Further,the substrate can be made of a material having a low coefficient ofthermal expansion (CTE), to avoid expansion of the plate as it is heatedup due to the heated build platform. In an embodiment, the material forthe substrate may be aluminum, steel, brass, ceramic, glass, or alloyssimilar with low coefficient of thermal expansion (CTE). Also, thesubstrate can have a thickness of at most about 0.1 inches (in), at mostabout 0.2 in, at most about 0.3 in, at most about 0.4 in, at most about0.5 in, at most about 0.6 in, at most about 0.7 in, at most about 0.8in, at most about 0.9 in, at most about 1 in, or at most about 5 in.Further, the thickness of the substrate may also depend on the flexuralcharacter of the material. The substrate may be thin enough to allow forminor flexing for the removal of the 3D object. Additionally, thesubstrate may not be too thin such that heating of the substrate resultsin rippling, bowing, or warping and resulting in a print surface that isuneven or not consistently level. Furthermore, the substrate may be ableto withstand high temperatures, such as at least about 50° C., at leastabout 100° C., at least about 150° C., at least about 200° C., at leastabout 250° C., at least about 300° C., at least about 350° C., or atleast about 400° C.

A high temperature polymer coating may be applied directly over thesurface of the substrate. The high temperature polymer may be selectedfrom the group consisting of polyether ether ketone, polyamide,polyimide, polyphenylene sulfide, polyphenylsulfone, polysulfone,polyether sulfone, polyethylenimine, polyetherimide,polytetrafluoroethylene, polyvinylidene, or any combination thereof. Thehigh temperature used for coating may be a polyimide. In an embodiment,the high temperature polymer coating may be spray coated over thesubstrate. The thickness of the polymer coating may be at most about0.005 in, at most about 0.01 in, at most about 0.05 in, at most about0.1 in, at most about 0.5 in, or at most about 0.1 in. The hightemperature polymer coating may not wear away and thus may not need tobe replaced after every build under high temperature. Advantageously,the high temperature polymer coating can operate at temperatures of atleast about 50° C., at least about 100° C., at least about 150° C., atleast about 200° C., at least about 250° C., at least about 300° C., atleast about 350° C., or at least about 400° C. The high temperaturepolymer coating may additionally be roughened or treated. The surface ofthe high temperature polymer coating may comprise a regular or anirregular patterned feature. In an embodiment, the surface of the hightemperature polymer coating 106 may be roughened at the nano-, micro-,or milli-meter scale using methods like and not limited to sandblasting, bead blasting, and/or metal wire brushing to increase polymeradhesion to the coated surface.

The substrate may possess flexibility owing to the type of material itis made of. The flexibility of the substrate may allow for easierdissociation between the 3D object and the substrate upon cooling.Further, this flexibility can also reduce the possibility of damage tothe high temperature polymer coating or the 3D object during objectremoval since a blade or wedge is no longer needed to pry off theobject. Once the printing of the 3D object is completed, the 3D objectmay pop off the substrate when the substrate and 3D object has cooled.

In some embodiments, the system for printing at least a portion of a 3Dobject may comprise one or more heater cartridges with thermal controlfrom PID controllers connected to thermocouples. The heater cartridgesmay function as a temperature control for the system. The one or morethermocouples can be situated at one or several locations to providefeedback to a controller, such as a PID controller, and hence maintaintemperature set points throughout a build. The system may comprise ajacket cover outside of the print head to contain and direct the flow ofthe hot fluid (e.g., hot air) towards the layers of the depositedportion of the 3D object.

The controller may be configured after deposition of a first layerand/or a second layer of at least a portion of the 3D object, and beforefusion is induced, to preheat the filament material to a temperaturesufficient to reduce undesirable shrinkage and/or to minimize the laserenergy needed to melt the next layer. For example, the preheating may beaccomplished using the infrared heater attached to substrate or throughother apparatuses of directing thermal energy within an enclosed spacearound the substrate. Alternatively, the preheating can be accomplishedusing energy beam melting by defocusing the energy beam and rapidlyscanning it over the deposited first layer and or second layer of atleast a portion of the 3D object.

In some embodiments, the controller may be configured using at least afirst energy beam from at least one energy source to selectively heatand/or melt at least a portion of the first layer and/or the secondlayer, thereby forming at least a portion of the 3D object. The energysource may be selected from the group consisting of a laser, a microwavesource, a resistive heating source, an infrared energy source, a UVenergy source, a hot fluid, a chemical reaction, a plasma source, amicrowave source, an electromagnetic source, an electron beam, or anycombination thereof. Resistive heating may be joule heating. A sourcefor resistive heating may be a power supply. The at least one filamentmaterial may be a metal filament. The at least one filament material maybe a metal filament composite. The deposited at least one filamentmaterial may be subjected to resistive heating upon flow of anelectrical current through the at least one filament material. Theresistive heating may be sufficient to melt at least a portion of thedeposited at least one filament material. The at least one filamentmaterial may be an electrode. The substrate may be another electrode.

The energy source may be a function of the chemical composition of thebuild material, such as the build material's thermal conductivity, heatcapacity, latent heat of fusion, melting point, and melt flow viscosity.The at least one energy source may be a laser. The laser may be selectedfrom the group consisting of gas lasers, chemical lasers, dye lasers,metal-vapor lasers, solid-state lasers, semiconductor lasers, freeelectron laser, gas dynamic laser, nickel-like samarium laser, Ramanlaser, nuclear pump laser, and any combination thereof. Gas lasers maycomprise one or more of helium-neon laser, argon laser, krypton laser,xenon ion laser, nitrogen laser, carbon dioxide laser, carbon monoxidelaser, and excimer laser. Chemical lasers may be selected from the groupconsisting of hydrogen fluoride laser, deuterium fluoride laser,chemical oxygen-iodine laser, all gas-phase iodine laser, and anycombination thereof. Metal-vapor lasers can comprise one or more ofhelium-cadmium, helium mercury, helium selenium, helium silver,strontium vapor laser, neon-copper, copper vapor laser, gold vaporlaser, and manganese vapor laser. Solid-state lasers may be selectedfrom the group consisting of ruby laser, neodymium-doped yttriumaluminium garnet laser, neodymium and chromium-doped yttrium aluminiumgarnet laser, erbium-doped yttrium aluminium garnet laser,neodymium-doped yttrium lithium fluoride laser, neodymium doped yttriumothovanadate laser, neodymium doped yttrium calcium oxoborate laser,neodymium glass laser, titanium sapphire laser, thulium yttriumaluminium garnet laser, ytterbium yttrium aluminium garnet laser,ytterbium:₂O₃ (glass or ceramics) laser, ytterbium doped glass laser(rod, plate/chip, and fiber), holmium yttrium aluminium garnet laser,chromium zinc selenium laser, cerium doped lithium strontium (orcalcium) aluminum fluoride laser, Promethium 147 doped phosphate glasssolid-state laser, chromium doped chrysoberyl (alexandrite) laser,erbium doped and erbium-ytterbium codoped glass lasers, trivalenturanium doped calcium fluoride solid-state laser, divalent samariumdoped calcium fluoride laser, FARBE center laser, and any combinationthereof. Semiconductor laser may comprise one or more of semiconductorlaser diode laser, gallium nitride laser, indium gallium nitride laser,aluminium gallium indium phosphide laser, aluminium gallium arsenidelaser, indium gallium arsenide phosphide laser, lead salt laser,vertical cavity surface emitting laser, quantum cascade laser, andhybrid silicon laser.

The melting temperature of the at least one filament material can be atleast about 150° C., at least about 200° C., at least about 250° C., atleast about 300° C., at least about 350° C., at least about 400° C., atleast about 450° C. The sintering temperature can be at most about 150°C., at most about 200° C., at most about 250° C., at most about 300° C.,at most about 350° C., at most about 400° C. The controller may furtherbe programmed to separate the remainder of the layer that did not fuseand solidify to form at least a portion of the three dimensional object,from the portion. The controller may be programmed to direct delivery ofthe three dimensional object to a customer. The controller may beprogrammed to direct packaging the three dimensional object.

The controller may be programmed to direct at least one energy beam fromthe energy source may be directed to the at least one portion of the 3Dobject adjacent to the substrate. Such energy beams may be sufficient toinduce fusion of particles of the filament material within the desiredcross-sectional geometry of the at least one portion of the 3D object.As the energy dissipates with cooling, atoms from neighboring particlesmay fuse together. In some embodiments, the at least one energy beamresults in the fusion of particles of filament material both within thesame layer and in the previously formed and resolidified adjoininglayer(s) such that fusion is induced between at least two adjacentlayers of the part, such as between at least one filament material in adeposited unfused layer and a previously-fused adjacent layer. Thecontroller may be further programmed to repeat such process overmultiple cycles as each part layer is added, until the full 3D object isformed.

In some cases, to create a melt pool large enough to span the width ofthe filament material segment, multiple energy sources or a combinationof energy sources may be required. When multiple energy sources areused, the energy sources may be the same energy source. Alternatively,the multiple energy sources may be different energy sources. The energysource(s) may be separate from the system for printing at least aportion of the 3D object. In some other embodiments, the energysource(s) may be integrated with such system. For example, in oneembodiment, a hot fluid may be channeled through the deposition nozzle.Because the material filament can flow in the melt pool, features of the3D object being built can be altered. In some embodiments, the melt poolmay be formed within the build object, such that a melt pool is notformed near the perimeters thereof. To accomplish this, the energysource may be turned off when the perimeters of the object are beingbuilt. In such embodiments, the geometrical tolerance of the buildobject may be maintained while the interior of the object has enhancedinterlayer bonding. During printing, the filament material may beprinted in the X, Y, and Z directions in one segment or layer.

The controller may be programmed to direct the processes of opticalcommunication between at least one energy source and one or more beamsplitters, which one or more beam splitters can split an energy beamfrom at least one light source into one or more beamlets that yields atleast the first energy beam. The controller can be programmed to directthe example optical system of FIG. 3 to receive in an opening 301,split, and direct such energy beams at various angles to the plane ofthe substrate 208 of system 200. System 300 can comprise one or morebeam splitters 302, one or more focusing lenses 303, one or more opticalwedges 304, and any combination thereof. The optical system 300 mayallow the energy beams to be aligned at any angle in the plane ofdeposition. The optical system may further comprise a beam expandingsystem and a spatial light modulator. At least the first energy beam maybe emitted by at least one light source and expanded by the beamexpanding system into parallel light beams having a large diameter bythe beam expanding system. Then, such parallel energy beams mayirradiate onto the one or more beam splitters. A part of the expandedenergy beams may reach a spatial modulator for modulation after passingthrough the beam splitter and the modulated energy beams can bereflected to the beam splitter. A part of the modulated energy beam maybe focused by the focusing system, angled by the optical wedges, andirradiated along the at least one filament material forthree-dimensional printing. The beam expanding system may comprise anegative lens and a positive lens. Furthermore, the spatial lightmodulator can be a reflector type digital micro-mirror device or a phasetype liquid crystal spatial light modulator.

One or more beam splitters may be selected from the group consisting ofprism, glass sheet, plastic sheet, mirror, dielectric mirror,metal-coated mirror, partially reflecting mirror, pellicles, micro-opticbeam splitters, waveguide beam splitters, beam splitter cubes,fiber-optic beam splitter, and any combination thereof. The controllermay be programmed so that one or more optical wedges may be in opticalcommunication with one or more beam splitters, which one or more opticalwedges form at least the first light beam. Such optical wedges can format least the first light beam in a uniform orientation. The one or morebeamlets may pass through one or more focusing lenses prior to passingthrough at least one or more optical wedges. Such beamlets may have anelliptical polarization. The one or more beamlets may comprise a minoraxis of at least about 0.5 mm, at least about 1 mm, at least about 2 mm,at least about 3 mm, at least about 4 mm, at least about 5 mm, at leastabout 6 mm, at least about 7 mm, at least about 8 mm, at least about 9mm, at least about 10 mm, or at least about 15 mm. The one or morebeamlets may also comprise a major axis of at least about 5 mm, at leastabout 10 mm, at least about 15 mm, at least about 20 mm, at least about25 mm, at least about 30 mm, at least about 35 mm, at least about 40 mm,at least about 45 mm, or at least about 50 mm. Such energy beams cancover at least a portion of at least one filament material. The one ormore focusing lenses may be used to adjust a ratio of the minor axis tothe major axis of the one or more beamlets.

The controller can further be programmed so that the optical wedges mayalter the path of the beam from vertical to any angle for uniformheating of the filament material. The controller may be programmed sothat one or more optical wedges can further direct an optical path of atleast the first light beam of a given location, direction, or anglenormal to the substrate and/or along the substrate among one or morelocations, directions, or angles. Such a direction of one or moreoptical wedges can allow for control of the heat from the light beamalong the at least one filament material.

The system for printing at least a portion of a three-dimensional (3D)object may further comprise one or more optical wedges in combinationwith one or more of dispersive prism, reflective prism, beam-splittingprism, polarizing prism, or deflecting prisms. Dispersive prisms may beused to break up light into its constituent spectral colors because therefractive index depends on frequency. Examples of dispersive prismsinclude Triangular prism, Abbe prism, Pellin-Broca prism, Amici prism,Compound prism, or Grism prism. Reflective prisms can be used to reflectlight, in order to flip, invert, rotate, deviate or displace the lightbeam. Examples of reflective prisms include Porro prism, Porro-Abbeprism, Amici roof prism, Pentaprism, Roof Pentaprism, Abbe-Koenig prism,Schmidt-Pechan prism, Bauernfeind prism, Dove prism, or Retroreflectorprism. Some reflective prisms may be used for splitting a beam into twoor more beams. Beam-splitting prisms may be a beam splitter cube or adichronic prism. Polarizing prisms can split a beam of light intocomponents of varying polarization. Examples of polarizing prisms may beNicol prism, Wollaston prism, Nomarski prism, Rochon prism, Senarmontprism, Glan-Foucault prism, Glan-Taylor prism, or Glan-Thompson prism.Deflecting prisms may be one or more of a Risley prism pair, Rhomboidprisms, or Deck prisms. Wedge prisms may be used to deflect a beam oflight by a fixed angle. A pair of such prisms can be used for beamsteering; by rotating the prisms the beam can be deflected into anydesired angle. The deflecting prism may be a Risley prism pair. Twowedge prisms can also be used as an anamorphic pair to change the shapeof a beam. For example, this may be used to generate a round beam fromthe elliptical output of a laser diode.

The one or more optical wedges can have a refractive index of at leastabout 0.5, at least about 1, at least about 1.1, at least about 1.2, atleast about 1.3, at least about 1.4, at least about 1.5, at least about1.6, at least about 1.7, at least about 1.8, at least about 1.9, atleast about 2.5, at least about 3, at least about 4, or at least about5. Such optical wedges can have a diameter of at most about 0.1 inches(in), at most about 0.2 in, at most about 0.3 in, at most about 0.4 in,at most about 0.5 in, at most about 0.6 in, at most about 0.7 in, atmost about 0.8 in, at most about 0.9 in, at most about 1 in, at mostabout 2 in, at most about 3 in, at most about 4 in, or at most about 5in.

In some embodiments, the controller can be programmed so that at leastthe first energy beam may be incident on at least one filament materialand on the substrate. Such energy beams may be directed along a givenangle among one or more angles relative to the dispensing route of atleast one filament material. The one or more optical wedges can comprisea first optical wedge and a second optical wedge. The first opticalwedge may be the top wedge and the second optical wedge may be thebottom wedge. Through choosing the wedge angle, the energy beams can bemade incident on the filament at an angle to the plane of the substrate.By directing the controller to rotate the bottom optical wedge, theincident angle can be varied. By directing the controller to rotate boththe optical wedges, the angle of the line beam in the plane ofdeposition can be varied. For example, the controller may be programmedto direct the first optical wedge to rotate relative to the secondoptical wedge to change the direction of at least the first light beam.The controller may direct the first optical wedge and the second opticalwedge to be angled in the same direction to increase an angle of atleast the first energy beam with respect to a reference. The energy beammay be a light beam. The controller may direct the first optical wedgeand the second optical wedge to rotate in opposite directions to allowat least the first energy beam to pass vertically through the one ormore optical wedges. When altering an angle of incidence of the firstoptical wedge and the second optical wedge, or when altering a directionof the major axis of at least the first energy beam relative to thesubstrate or at least one filament material, the controller may directthe fluence of at least the first light beam to be altered. As a result,such light beams may heat at least one filament material without meltinga deposited portion of the at least one filament material. In someinstances, the controller may direct the at least the first energy beamto heat and melt a deposited portion of at least one filament materialat a given location among one or more locations.

In other instances, the controller may program the at least one filamentmaterial to be directed to a compaction unit. Such filament material maybe compacted by such a compaction unit to form at least one compactedfilament material. The compaction unit may comprise a rigid body, one ormore idler rollers, at least one freely suspended roller, a coolantunit, or any combination thereof. The at least one freely suspendedroller may be a compaction roller. The controller may direct the rigidbody and one or more idler rollers to secure the at least one freelysuspended roller. Such freely suspended rollers may have a diameter ofat most about 1 mm, at most about 2 mm, at most about 3 mm, at mostabout 4 mm, at most about 5 mm, at most about 6 mm, at most about 7 mm,at most about 8 mm, at most about 9 mm, at most about 10 mm, or at mostabout 15 mm. The controller may direct the coolant to cool thecompaction unit so the at least one filament material does not stick tothe roller and adheres to the previously deposited layer of thethree-dimensional object.

The system for printing at least a portion of the 3D object may furthercomprise one or more cooling components. Such cooling components may bein proximity to the deposited filament material layer. Such coolingcomponents can be located between the deposited filament material layerand the energy source. Such cooling components may be movable to or froma location that may be positioned between the filament material and theenergy source. Such cooling components may assist in the process ofcooling of the fused portion of the filament material layer. Suchcooling components may also assist in the cooling of the filamentmaterial layer remainder that did not fuse to subsequently form at leasta portion of the 3D object. Such cooling components can assist in thecooling of the at least a portion of the 3D object and the remainder atconsiderably the same rate. Such cooling components may be separatedfrom the filament material layer and/or from the substrate by a gap. Thegap may comprise a gas. The gap can have a cross-section that is at mostabout 0.1 mm, at most about 0.5 mm, at most about 1 mm, at most about 5mm, or at most about 10 mm. The gap can be adjustable. The controllermay be operatively connected to such cooling components and may be ableto adjust the gap distance from the substrate. Such cooling componentscan track an energy that may be applied to the portion of the filamentmaterial layer by the energy source. Such cooling components maycomprise a heat sink. Such cooling components may be a cooling fan. Thecontroller may be operatively coupled to such cooling components andcontrols the tracing of such cooling components. Such cooling componentsmay include at least one opening though which at least one energy beamfrom the energy source can be directed to the portion of the filamentlayer. The system for printing at least a portion of the 3D object canfurther comprise an additional energy source that provides energy to aremainder of the filament material layer that did not fuse tosubsequently form at least a portion of the 3D object.

During printing of the three-dimensional object, certain parameters maybe critical to printing high quality parts. One or more sensors can beused to measure one or more temperature(s) along at least one filamentmaterial. Such sensors can control intensities, positions, and/or anglesof at least the first energy beam. The one or more sensors may be anoptical pyrometer. The controller may direct the optical pyrometers tobe aimed at the nip points and one or more points before and/or afterthe compaction unit to detect the temperature of the at least onefilament materials as they are deposited. The temperature may vary fromregion to region of the filament material layer. Factors that affecttemperature variance can include variable heater irradiance, variationsin absorptivity of the composition, substrate temperature, filamentmaterial temperature, unfused filament material temperature, and the useof modifiers and additives. Accordingly, the controller may beprogrammed so that the image and temperature measurement inputs basedupon layer temperature patterns captured by the one or more sensors maybe used. The real time temperature inputs and the sintering model may befactors determining an energy requirement pattern for any one or moresubsequent layers.

Additionally, the system may comprise a real time simulation program, asample as shown in FIG. 4, to provide feedback control of a givenlocation, direction, or angle of at least the first energy beam normalto the substrate and/or along the substrate among one or more locations,directions, or angles. The sample real time simulation of the opticalbeam path illustrates that choosing the appropriate wedge angle andenergy beam orientation may result in the elliptical beam profile inFIG. 4. The real time simulation program may be a feedback controlsystem. The feedback control system may be a Zemax simulation of thebeam propagation.

Other parameters critical to printing high quality parts can includesubstrate temperature, melt zone temperature, as-built geometry, surfaceroughness and texture and density. Other critical visible or non-visiblemetrics include characterization of chemistry, bonding or adhesionstrength. Measuring one or more structural or internal properties of thepart can comprise one or more methods selected from the group consistingof scattered and reflected or absorbed radiation, x-ray imaging, soundwaves, scatterometry techniques, ultrasonic techniques, X-rayPhotoelectron Spectroscopy (XPS), Four Transform Infrared Spectroscopy(FTIR), Raman Spectroscopy, Laser-Microprobe Mass Spectrometry (LMMS),and any combination thereof. Specific metrology beneficial to the endgoals of characterizing the critical process parameters can be used.This in-situ metrology coupled with fast processing of data can enableopen or closed loop control of the manufacturing process. Sensorsappropriate to the key parameters of interest can be selected andutilized during the part printing process. The sensors may also comprisea camera for detecting light in the infrared or visible portion of theelectromagnetic spectrum. Sensors such as IR cameras may be used tomeasure temperature fields. An image processing algorithm may be used toevaluate data generated by one or more sensors, to extract one or morestructural or internal properties of the part. Visual (e.g., highmagnification) microscopy from digital camera(s) can be used with propersoftware processing to detect voids, defects, and surface roughness. Inorder to utilize this technique, potentially large quantities of datamay need to be interrogated using image processing algorithms in orderto extract features of interest. Scatterometry techniques may be adaptedto provide roughness or other data.

Ultrasonic techniques can be used to measure solid density and fiber andparticle density which in turn may be useful in characterizing bondstrength and fiber dispersion. The characterization can affect materialstrength. Ultrasonic techniques can also be used to measure thickness offeatures. Chemical bonding characterization, which may be useful forunderstanding fiber and/or matrix adhesion and layer-to-layer bonding,can be performed by multiple techniques such as XPS (X-ray PhotoelectronSpectroscopy), FTIR (Four Transform Infrared Spectroscopy) and RamanSpectroscopy and Laser-Microprobe Mass Spectrometry (LMMS). One or moreof these techniques may be utilized as part of the in-situ metrology for3D printing. Ex-situ techniques may also be utilized in order to helpprovide appropriate calibration data for the in-situ techniques.

Sensors may be positioned on the robot end-effector of thethree-dimensional printer in order to provide a sensor moving along withthe deposited material. A robot end-effector may be a device positionedat the end of a robotic arm. The robot end-effector may be programmed tointeract with its surrounding environment. Sensors may be also locatedat other various positions. The positions can be on-board the robot, onthe effector, or deployed in the environment. Sensors may be incommunication with the system. The system can further comprise one ormore processors, a communication unit, memory, power supply, andstorage. The communications unit can comprise an input and an output.The communication unit can be wired or wireless. The sensor measurementsmay or may not be stored in a database, and may or may not be used infuture simulation and optimization operations. In-situ measurements mayalso be made using alternative methods with sensors in a cell but notdirectly attached to the robot end-effector.

In another aspect, the present disclosure provides a system for printingat least a portion of a 3D object. The system may comprise a source ofat least one filament material that is configured to supply at least onefilament material for generating the 3D object. The system may comprisea substrate for supporting at least a portion of the 3D object. Thesystem may additionally comprise at least one energy source configuredto deliver at least a first energy beam. The system can comprise acontroller operatively coupled to at least one energy source, whereinthe controller is programmed to (i) receive, in computer memory, a modelof the 3D object, (ii) subsequent to receiving the model of the 3Dobject, direct at least one filament material from the source of atleast one filament material towards the substrate that is configured tosupport the 3D object, thereby depositing a first layer corresponding toa portion of the 3D object adjacent to the substrate, which first layeris deposited in accordance with the model of the 3D object, (iii) use atleast a first energy beam from at least one energy source to melt atleast a portion of the first layer, and (iv) deposit a second layercorresponding to at least a portion of the 3D object, which second layeris deposited in accordance with a model of the 3D object, therebygenerating at least a portion of the 3D object. In some cases, thecontroller may be programmed to perform fused deposition modeling whenprinting the 3D object. In other cases, the controller may be programmedto print the 3D object with extrusion. In some cases, the controller maybe programmed to print the 3D object without extrusion. The controllercan be further programmed to repeat (ii)-(iv) one or more times.

The system may further comprise an opening for (i) receiving at leastone filament material, and (ii) directing at least one filament materialtowards the substrate.

The layered structure can comprise substantially repetitive layers. Thelayers may have an average layer size of at least about 0.5 μm, 1 μm, 5μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, 450 μm, 500 μm, 1mm, 25 mm, 50 mm, 100 mm, 500 mm, or 1 m. The layers may have an averagelayer size of at most about 50 m, 1 m, 500 mm, 100 mm, 50 mm, 25 mm, 1mm, 500 μm, 450 μm, 400 μm, 350 μm, 300 μm, 250 μm, 200 μm, 150 μm, 100μm, 90 μm, 80 μm, 70 μm, 60 μm, 50 μm, 40 μm, 30 μm, 20 μm, or 10 μm.The layers may have an average layer size of any value between theaforementioned values of layer size. For example, the layers may have anaverage layer size from about 0.5 μm to about 500 mm, from about 15 μmto about 100 μm, from about 5 μm to about 300 μm, from about 20 μm toabout 90 μm, or from about 10 μm to about 70 μm. The layered structurecan be indicative of layered deposition. The layered structure can beindicative of solidification of melt pools formed during a threedimensional printing process. The structure indicative of a threedimensional printing process can comprise substantially repetitivevariation comprising: variation in grain orientation, variation inmaterial density, variation in the degree of compound segregation tograin boundaries, variation in the degree of element segregation tograin boundaries, variation in material phase, variation inmetallurgical phase, variation in material porosity, variation incrystal phase, or variation in crystal structure. The melt pools may beindicative of an additive manufacturing process comprisingstereolithography (SLA), selective laser melting (SLM), selective lasersintering (SLS), digital light processing (DLP), electron beam melting(EBM), laminated object manufacturing (LOM), binder jetting (BM),material jetting/wax casting (MJ), direct metal laser sintering (DMLS),or fused deposition modeling (FDM). The melt pools may be indicative ofan additive manufacturing process comprising selective energy melting.

The source of at least one filament material may be configured to supplyat least one filament material for generating the three-dimensionalobject. The at least one filament material may be stored on one or morespools or cartridges. The spools and/or cartridges may be replaceable.The at least one filament material may be a composite material, such asa continuous fiber composite. The filament material may be nano milled,short, long, continuous, or a combination thereof. The continuous fibercomposite may be a continuous core reinforced filament. The continuouscore reinforced filament can comprise a towpreg that is substantiallyvoid free and includes a polymer that coats or impregnates an internalcontinuous core. Depending upon the particular embodiment, the core maybe a solid core or it may be a multi-strand core comprising multiplestrands. The continuous fiber composite may be selected from the groupconsisting of glass, carbon, aramid, cotton, silicon carbide, polymer,wool, metal, and any combination thereof.

The filament material may incorporate one or more additional materials,such as resins and polymers. For example, appropriate resins andpolymers include, but are not limited to, acrylonitrile butadienestyrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI),Polyaryletherketone (PAEK), Polyether ether ketone (PEEK), PolyacticAcid (PLA), Liquid Crystal Polymer, polyamide, polyimide, polyphenylenesulfide, polyphenylsulfone, polysulfone, polyether sulfone,polyethylenimine, polytetrafluoroethylene, polyvinylidene, and variousother thermoplastics. The core of the continuous fiber composite may beselected to provide any desired property. Appropriate core fiber orstrands include those materials which impart a desired property, such asstructural, conductive (electrically and/or thermally), insulative(electrically and/or thermally), optical and/or fluidic transport. Suchmaterials include, but are not limited to, carbon fibers, aramid fibers,fiberglass, metals (such as copper, silver, gold, tin, and steel),optical fibers, and flexible tubes. The core fiber or strands may beprovided in any appropriate size. Further, multiple types of continuouscores may be used in a single continuous core reinforced filament toprovide multiple functionalities such as electrical and opticalproperties. A single material may be used to provide multiple propertiesfor the core reinforced filament. For example, a steel core may be usedto provide both structural properties as well as electrical conductivityproperties.

Alternatively, the filament material may comprise metal particlesinfused into a binder matrix. The metal particles may be metal powder.The binder matrix may include resins or polymers. Additionally, suchbinder matrix can be used a delivery device for the metal particles.Once the filament material is deposited onto the base, one or moreenergy sources can heat and melt the binder matrix, leaving the metalparticles to melt and fuse into larger metal particles. Such energysources may be without limitation, a laser, a microwave source, aresistive heating source, an infrared energy source, a UV energy source,a hot fluid, a chemical reaction, a plasma source, a microwave source,an electromagnetic source, or an electron beam. Resistive heating may bejoule heating. A source for resistive heating may be a power supply. Theat least one filament material may be a metal filament. The at least onefilament material may be a metal filament composite. The deposited atleast one filament material may be subjected to resistive heating uponflow of an electrical current through the at least one filamentmaterial. The resistive heating may be sufficient to melt at least aportion of the deposited at least one filament material. The at leastone filament material may be an electrode. The substrate may be anotherelectrode.

The one or more energy sources may also provide localized heating tocreate a “melt pool” in the current layer or segment of the depositedbuild material prior to depositing the next segment or layer. The meltpool can increase diffusion and mixing of the build material betweenadjacent layers (e.g., across a direction orthogonal to the layers) ascompared to other methods which deposit a subsequent layer of buildmaterial on top of a layer of build material that is below its meltingtemperature.

The increased diffusion and mixing resulting from the melt pool mayincrease the chemical chain linkage, bonding, and chemical chaininteractions between the two layers. This can result in increasing thebuild-material adhesion in the Z direction, thereby enhancingmechanical, thermal, and electrical properties of the three-dimensionalobject. The melt pool can also reduce the void space and porosity in thebuild object. Among other benefits, this decrease in porosity may alsocontribute to the aforementioned improvement in mechanical, thermal, andelectrical properties.

The at least one filament material may have a cross sectional shapeselected from the group consisting of circle, ellipse, parabola,hyperbola, convex polygon, concave polygon, cyclic polygon, equilateralpolygon, equiangular polygon, regular convex polygon, regular starpolygon, tape-like geometry, and any combination thereof. Such filamentmaterial can have a diameter of at most about 0.1 millimeters (mm), atmost about 0.2 mm, at most about 0.3 mm, at most about 0.4 mm, at mostabout 0.5 mm, at most about 0.6 mm, at most about 0.7 mm, at most about0.8 mm, at most about 0.9 mm, at most about 1 mm, at most about 2 mm, atmost about 3 mm, at most about 4 mm, at most about 5 mm, at most about10 mm, or at most about 20 mm.

Various modifiers within the layers themselves may be used which areselectively printed onto specific regions of the 3D object in order toimpart various desirable mechanical, chemical, magnetic, electrical orother properties to the 3D object. Such modifiers may be selected fromthe group consisting of thermal conductors and insulators, dielectricpromoters, electrical conductors and insulators, locally-containedheater traces for multi-zone temperature control, batteries, andsensors. In some embodiments, at least one print head can be may be usedfor printing such modifiers. As desired, such modifiers can be printedbefore at least a first energy beam is directed onto at least a portionof the first layer and/or second layer. Alternatively, such modifiersmay be printed over a layer that has been melted, before filamentmaterial for the next layer is deposited.

For example, when printing a polyimide part from commercially availablea filament comprising polyimide, an array of electrically conductivetraces may be assimilated as an antenna to selectively absorbradiofrequency (RF) radiation within a specific and predeterminedfrequency range. The 3D object CAD model and software can designate as asub-part the layer(s) that comprise the traces for modified properties(high electrical conductivity). Alternatively, if these portions of thelayer entail different levels of energy for inducing fusion, compared toother regions having only the primary material, the CAD model and designof the 3D object may be adjusted accordingly.

In some embodiments, the system for printing at least a portion of athree-dimensional object may comprise at least one print head. The atleast one print head may comprise one or more dies for extrusion. The atleast one print head also deposit printed material without extrusion.

In some embodiments, the system for printing at least a portion of athree-dimensional object may comprise a build plate form. The system mayalso comprise a substrate. The substrate may be able to withstand hightemperatures. The substrate may have high thermal tolerances, and ableto withstand high temperatures, such as at least about 50° C., at leastabout 100° C., at least about 150° C., at least about 200° C., at leastabout 250° C., at least about 300° C., at least about 350° C., or atleast about 400° C.

The substrate may be a non-removable. The substrate may be a removableplate secured over the build platform. In an embodiment, guidinglegs/rails may be used to slide the removable plate into multiplegrooves and multiple set screws and fasteners to secure the plate ontothe build platform. In another embodiment, the spring/latchquick-release mechanism may be used to secure in place and remove theplate. The method to secure the plate may also be vacuum suction of theplate onto build platform. The method to secure the plate can be magnetsand/or electromagnets.

The substrate may be thermally conductive in nature, so that it can beheated. The substrate can be heated from the heated build platform bythe temperature control components, such as heater cartridges. Further,the substrate can be made of a material having a low coefficient ofthermal expansion (CTE), to avoid expansion of the plate as it is heatedup due to the heated build platform. In an embodiment, the material forthe substrate may be aluminum, steel, brass, ceramic, glass, or alloyssimilar with low coefficient of thermal expansion (CTE). Also, thesubstrate can have a thickness of at most about 0.1 inches (in), at mostabout 0.2 in, at most about 0.3 in, at most about 0.4 in, at most about0.5 in, at most about 0.6 in, at most about 0.7 in, at most about 0.8in, at most about 0.9 in, at most about 1 in, or at most about 5 in.Further, the thickness of the substrate may also depend on the flexuralcharacter of the material. The substrate may be thin enough to allow forminor flexing for the removal of the 3D object. Additionally, thesubstrate may not be too thin such that heating of the substrate resultsin rippling, bowing, or warping and resulting in a print surface that isuneven or not consistently level. Furthermore, the substrate may be ableto withstand high temperatures, such as at least about 50° C., at leastabout 100° C., at least about 150° C., at least about 200° C., at leastabout 250° C., at least about 300° C., at least about 350° C., or atleast about 400° C.

A high temperature polymer coating may be applied directly over thesurface of the substrate. The high temperature polymer may be selectedfrom the group consisting of polyether ether ketone, polyamide,polyimide, polyphenylene sulfide, polyphenylsulfone, polysulfone,polyether sulfone, polyethylenimine, polyetherimide,polytetrafluoroethylene, polyvinylidene, or any combination thereof. Thehigh temperature used for coating may be a polyimide. In an embodiment,the high temperature polymer coating may be spray coated over thesubstrate. The thickness of the polymer coating may be at most about0.005 in, at most about 0.01 in, at most about 0.05 in, at most about0.1 in, at most about 0.5 in, or at most about 0.1 in. The hightemperature polymer coating may not wear away and thus may not need tobe replaced after every build under high temperature. Advantageously,the high temperature polymer coating can operate at temperatures of atleast about 50° C., at least about 100° C., at least about 150° C., atleast about 200° C., at least about 250° C., at least about 300° C., atleast about 350° C., or at least about 400° C. The high temperaturepolymer coating may additionally be roughened or treated. The surface ofthe high temperature polymer coating may comprise a regular or anirregular patterned feature. In an embodiment, the surface of the hightemperature polymer coating 106 may be roughened at the nano-, micro-,or milli-meter scale using methods like and not limited to sandblasting, bead blasting, and/or metal wire brushing to increase polymeradhesion to the coated surface.

The substrate may possess flexibility owing to the type of material itis made of. The flexibility of the substrate may allow for easierdissociation between the 3D object and the substrate upon cooling.Further, this flexibility can also reduce the possibility of damage tothe high temperature polymer coating or the 3D object during objectremoval since a blade or wedge is no longer needed to pry off theobject. Once the printing of the 3D object is completed, the 3D objectmay pop off the substrate when the substrate and 3D object has cooled.

In some embodiments, the system for printing at least a portion of a 3Dobject may comprise one or more heater cartridges with thermal controlfrom PID controllers connected to thermocouples. The heater cartridgesmay function as a temperature control for the system. The one or morethermocouples can be situated at one or several locations to providefeedback to a controller, such as a PID controller, and hence maintaintemperature set points throughout a build. The system may comprise ajacket cover outside of the print head to contain and direct the flow ofthe hot fluid (e.g., hot air) towards the layers of the depositedportion of the 3D object.

The controller may be configured after deposition of a first layerand/or a second layer of at least a portion of the 3D object, and beforefusion is induced, to preheat the filament material to a temperaturesufficient to reduce undesirable shrinkage and/or to minimize the laserenergy needed to melt the next layer. For example, the preheating may beaccomplished using the infrared heater attached to substrate or throughother apparatuses of directing thermal energy within an enclosed spacearound the substrate. Alternatively, the preheating can be accomplishedusing energy beam melting by defocusing the energy beam and rapidlyscanning it over the deposited first layer and or second layer of atleast a portion of the 3D object.

In some embodiments, the controller may be configured using at least afirst energy beam from at least one energy source to selectively heatand/or melt at least a portion of the first layer and/or the secondlayer, thereby forming at least a portion of the 3D object. The energysource may be selected from the group consisting of a laser, a microwavesource, a resistive heating source, an infrared energy source, a UVenergy source, a hot fluid, a chemical reaction, a plasma source, amicrowave source, an electromagnetic source, an electron beam, or anycombination thereof. Resistive heating may be joule heating. A sourcefor resistive heating may be a power supply. The at least one filamentmaterial may be a metal filament. The at least one filament material maybe a metal filament composite. The deposited at least one filamentmaterial may be subjected to resistive heating upon flow of anelectrical current through the at least one filament material. Theresistive heating may be sufficient to melt at least a portion of thedeposited at least one filament material. The at least one filamentmaterial may be an electrode. The substrate may be another electrode.

The energy source may be a function of the chemical composition of thebuild material, such as the build material's thermal conductivity, heatcapacity, latent heat of fusion, melting point, and melt flow viscosity.The at least one energy source may be a laser. The laser may be selectedfrom the group consisting of gas lasers, chemical lasers, dye lasers,metal-vapor lasers, solid-state lasers, semiconductor lasers, freeelectron laser, gas dynamic laser, nickel-like samarium laser, Ramanlaser, nuclear pump laser, and any combination thereof. Gas lasers maycomprise one or more of helium-neon laser, argon laser, krypton laser,xenon ion laser, nitrogen laser, carbon dioxide laser, carbon monoxidelaser, and excimer laser. Chemical lasers may be selected from the groupconsisting of hydrogen fluoride laser, deuterium fluoride laser,chemical oxygen-iodine laser, all gas-phase iodine laser, and anycombination thereof. Metal-vapor lasers can comprise one or more ofhelium-cadmium, helium mercury, helium selenium, helium silver,strontium vapor laser, neon-copper, copper vapor laser, gold vaporlaser, and manganese vapor laser. Solid-state lasers may be selectedfrom the group consisting of ruby laser, neodymium-doped yttriumaluminium garnet laser, neodymium and chromium-doped yttrium aluminiumgarnet laser, erbium-doped yttrium aluminium garnet laser,neodymium-doped yttrium lithium fluoride laser, neodymium doped yttriumothovanadate laser, neodymium doped yttrium calcium oxoborate laser,neodymium glass laser, titanium sapphire laser, thulium yttriumaluminium garnet laser, ytterbium yttrium aluminium garnet laser,ytterbium:₂O₃ (glass or ceramics) laser, ytterbium doped glass laser(rod, plate/chip, and fiber), holmium yttrium aluminium garnet laser,chromium zinc selenium laser, cerium doped lithium strontium (orcalcium) aluminum fluoride laser, Promethium 147 doped phosphate glasssolid-state laser, chromium doped chrysoberyl (alexandrite) laser,erbium doped and erbium-ytterbium codoped glass lasers, trivalenturanium doped calcium fluoride solid-state laser, divalent samariumdoped calcium fluoride laser, FARBE center laser, and any combinationthereof. Semiconductor laser may comprise one or more of semiconductorlaser diode laser, gallium nitride laser, indium gallium nitride laser,aluminium gallium indium phosphide laser, aluminium gallium arsenidelaser, indium gallium arsenide phosphide laser, lead salt laser,vertical cavity surface emitting laser, quantum cascade laser, andhybrid silicon laser.

The melting temperature of the at least one filament material can be atleast about 150° C., at least about 200° C., at least about 250° C., atleast about 300° C., at least about 350° C., at least about 400° C., atleast about 450° C. The sintering temperature can be at most about 150°C., at most about 200° C., at most about 250° C., at most about 300° C.,at most about 350° C., at most about 400° C. The controller may furtherbe programmed to separate the remainder of the layer that did not fuseand solidify to form at least a portion of the three dimensional object,from the portion. The controller may be programmed to direct delivery ofthe three dimensional object to a customer. The controller may beprogrammed to direct packaging the three dimensional object.

The controller may be programmed to direct at least one energy beam fromthe energy source may be directed to the at least one portion of the 3Dobject adjacent to the substrate. Such energy beams may be sufficient toinduce fusion of particles of the filament material within the desiredcross-sectional geometry of the at least one portion of the 3D object.As the energy dissipates with cooling, atoms from neighboring particlesmay fuse together. In some embodiments, the at least one energy beamresults in the fusion of particles of filament material both within thesame layer and in the previously formed and resolidified adjoininglayer(s) such that fusion is induced between at least two adjacentlayers of the part, such as between at least one filament material in adeposited unfused layer and a previously-fused adjacent layer. Thecontroller may be further programmed to repeat such process overmultiple cycles as each part layer is added, until the full 3D object isformed.

In some cases, to create a melt pool large enough to span the width ofthe filament material segment, multiple energy sources or a combinationof energy sources may be required. When multiple energy sources areused, the energy sources may be the same energy source. Alternatively,the multiple energy sources may be different energy sources. The energysource(s) may be separate from the system for printing at least aportion of the 3D object. In some other embodiments, the energysource(s) may be integrated with such system. For example, in oneembodiment, a hot fluid may be channeled through the deposition nozzle.Because the material filament can flow in the melt pool, features of the3D object being built can be altered. In some embodiments, the melt poolmay be formed within the build object, such that a melt pool is notformed near the perimeters thereof. To accomplish this, the energysource may be turned off when the perimeters of the object are beingbuilt. In such embodiments, the geometrical tolerance of the buildobject may be maintained while the interior of the object has enhancedinterlayer bonding. During printing, the filament material may beprinted in the X, Y, and Z directions in one segment or layer.

The controller may be programmed to direct the processes of opticalcommunication between at least one energy source and one or more beamsplitters, which one or more beam splitters can split an energy beamfrom at least one light source into one or more beamlets that yields atleast the first energy beam. The controller can be programmed to directthe example optical system of FIG. 3 to receive in an opening 301,split, and direct such energy beams at various angles to the plane ofthe substrate 208 of system 200. System 300 can comprise one or morebeam splitters 302, one or more focusing lenses 303, one or more opticalwedges 304, and any combination thereof. The optical system 300 mayallow the energy beams to be aligned at any angle in the plane ofdeposition. The optical system may further comprise a beam expandingsystem and a spatial light modulator. At least the first energy beam maybe emitted by at least one light source and expanded by the beamexpanding system into parallel light beams having a large diameter bythe beam expanding system. Then, such parallel energy beams mayirradiate onto the one or more beam splitters. A part of the expandedenergy beams may reach a spatial modulator for modulation after passingthrough the beam splitter and the modulated energy beams can bereflected to the beam splitter. A part of the modulated energy beam maybe focused by the focusing system, angled by the optical wedges, andirradiated along the at least one filament material forthree-dimensional printing. The beam expanding system may comprise anegative lens and a positive lens. Furthermore, the spatial lightmodulator can be a reflector type digital micro-mirror device or a phasetype liquid crystal spatial light modulator.

One or more beam splitters may be selected from the group consisting ofprism, glass sheet, plastic sheet, mirror, dielectric mirror,metal-coated mirror, partially reflecting mirror, pellicles, micro-opticbeam splitters, waveguide beam splitters, beam splitter cubes,fiber-optic beam splitter, and any combination thereof. The controllermay be programmed so that one or more optical wedges may be in opticalcommunication with one or more beam splitters, which one or more opticalwedges form at least the first light beam. Such optical wedges can format least the first light beam in a uniform orientation. The one or morebeamlets may pass through one or more focusing lenses prior to passingthrough at least one or more optical wedges. Such beamlets may have anelliptical polarization. The one or more beamlets may comprise a minoraxis of at least about 0.5 mm, at least about 1 mm, at least about 2 mm,at least about 3 mm, at least about 4 mm, at least about 5 mm, at leastabout 6 mm, at least about 7 mm, at least about 8 mm, at least about 9mm, at least about 10 mm, or at least about 15 mm. The one or morebeamlets may also comprise a major axis of at least about 5 mm, at leastabout 10 mm, at least about 15 mm, at least about 20 mm, at least about25 mm, at least about 30 mm, at least about 35 mm, at least about 40 mm,at least about 45 mm, or at least about 50 mm. Such energy beams cancover at least a portion of at least one filament material. The one ormore focusing lenses may be used to adjust a ratio of the minor axis tothe major axis of the one or more beamlets.

The controller can further be programmed so that the optical wedges mayalter the path of the beam from vertical to any angle for uniformheating of the filament material. The controller may be programmed sothat one or more optical wedges can further direct an optical path of atleast the first light beam of a given location, direction, or anglenormal to the substrate and/or along the substrate among one or morelocations, directions, or angles. Such a direction of one or moreoptical wedges can allow for control of the heat from the light beamalong the at least one filament material.

The system for printing at least a portion of a three-dimensional (3D)object may further comprise one or more optical wedges in combinationwith one or more of dispersive prism, reflective prism, beam-splittingprism, polarizing prism, or deflecting prisms. Dispersive prisms may beused to break up light into its constituent spectral colors because therefractive index depends on frequency. Examples of dispersive prismsinclude Triangular prism, Abbe prism, Pellin-Broca prism, Amici prism,Compound prism, or Grism prism. Reflective prisms can be used to reflectlight, in order to flip, invert, rotate, deviate or displace the lightbeam. Examples of reflective prisms include Porro prism, Porro-Abbeprism, Amici roof prism, Pentaprism, Roof Pentaprism, Abbe-Koenig prism,Schmidt-Pechan prism, Bauernfeind prism, Dove prism, or Retroreflectorprism. Some reflective prisms may be used for splitting a beam into twoor more beams. Beam-splitting prisms may be a beam splitter cube or adichronic prism. Polarizing prisms can split a beam of light intocomponents of varying polarization. Examples of polarizing prisms may beNicol prism, Wollaston prism, Nomarski prism, Rochon prism, Senarmontprism, Glan-Foucault prism, Glan-Taylor prism, or Glan-Thompson prism.Deflecting prisms may be one or more of a Risley prism pair, Rhomboidprisms, or Deck prisms. Wedge prisms may be used to deflect a beam oflight by a fixed angle. A pair of such prisms can be used for beamsteering; by rotating the prisms the beam can be deflected into anydesired angle. The deflecting prism may be a Risley prism pair. Twowedge prisms can also be used as an anamorphic pair to change the shapeof a beam. For example, this may be used to generate a round beam fromthe elliptical output of a laser diode.

The one or more optical wedges can have a refractive index of at leastabout 0.5, at least about 1, at least about 1.1, at least about 1.2, atleast about 1.3, at least about 1.4, at least about 1.5, at least about1.6, at least about 1.7, at least about 1.8, at least about 1.9, atleast about 2.5, at least about 3, at least about 4, or at least about5. Such optical wedges can have a diameter of at most about 0.1 inches(in), at most about 0.2 in, at most about 0.3 in, at most about 0.4 in,at most about 0.5 in, at most about 0.6 in, at most about 0.7 in, atmost about 0.8 in, at most about 0.9 in, at most about 1 in, at mostabout 2 in, at most about 3 in, at most about 4 in, or at most about 5in.

In some embodiments, the controller can be programmed so that at leastthe first energy beam may be incident on at least one filament materialand on the substrate. Such energy beams may be directed along a givenangle among one or more angles relative to the dispensing route of atleast one filament material. The one or more optical wedges can comprisea first optical wedge and a second optical wedge. The first opticalwedge may be the top wedge and the second optical wedge may be thebottom wedge. Through choosing the wedge angle, the energy beams can bemade incident on the filament at an angle to the plane of the substrate.By directing the controller to rotate the bottom optical wedge, theincident angle can be varied. By directing the controller to rotate boththe optical wedges, the angle of the line beam in the plane ofdeposition can be varied. For example, the controller may be programmedto direct the first optical wedge to rotate relative to the secondoptical wedge to change the direction of at least the first light beam.The controller may direct the first optical wedge and the second opticalwedge to be angled in the same direction to increase an angle of atleast the first energy beam with respect to the reference. The energybeam may be a light beam. The controller may direct the first opticalwedge and the second optical wedge to rotate in opposite directions toallow at least the first energy beam to pass vertically through the oneor more optical wedges. When altering an angle of incidence of the firstoptical wedge and the second optical wedge, or when altering a directionof the major axis of at least the first energy beam relative to thesubstrate or at least one filament material, the controller may directthe fluence of at least the first light beam to be altered. As a result,such light beams may heat at least one filament material without meltinga deposited portion of the at least one filament material. In someinstances, the controller may direct the at least the first energy beamto heat and melt a deposited portion of at least one filament materialat a given location among one or more locations.

In other instances, the controller may program the at least one filamentmaterial to be directed to a compaction unit. Such filament material maybe compacted by such a compaction unit to form at least one compactedfilament material. The compaction unit may comprise a rigid body, one ormore idler rollers, at least one freely suspended roller, a coolantunit, or any combination thereof. The at least one freely suspendedroller may be a compaction roller. The controller may direct the rigidbody and one or more idler rollers to secure the at least one freelysuspended roller. Such freely suspended rollers may have a diameter ofat most about 1 mm, at most about 2 mm, at most about 3 mm, at mostabout 4 mm, at most about 5 mm, at most about 6 mm, at most about 7 mm,at most about 8 mm, at most about 9 mm, at most about 10 mm, or at mostabout 15 mm. The controller may direct the coolant to cool thecompaction unit so the at least one filament material does not stick tothe roller and adheres to the previously deposited layer of thethree-dimensional object.

The system for printing at least a portion of the 3D object may furthercomprise one or more cooling components. Such cooling components may bein proximity to the deposited filament material layer. Such coolingcomponents can be located between the deposited filament material layerand the energy source. Such cooling components may be movable to or froma location that may be positioned between the filament material and theenergy source. Such cooling components may assist in the process ofcooling of the fused portion of the filament material layer. Suchcooling components may also assist in the cooling of the filamentmaterial layer remainder that did not fuse to subsequently form at leasta portion of the 3D object. Such cooling components can assist in thecooling of the at least a portion of the 3D object and the remainder atconsiderably the same rate. Such cooling components may be separatedfrom the filament material layer and/or from the substrate by a gap. Thegap may comprise a gas. The gap can have a cross-section that is at mostabout 0.1 mm, at most about 0.5 mm, at most about 1 mm, at most about 5mm, or at most about 10 mm. The gap can be adjustable. The controllermay be operatively connected to such cooling components and may be ableto adjust the gap distance from the substrate. Such cooling componentscan track an energy that may be applied to the portion of the filamentmaterial layer by the energy source. Such cooling components maycomprise a heat sink. Such cooling components may be a cooling fan. Thecontroller may be operatively coupled to such cooling components andcontrols the tracing of such cooling components. Such cooling componentsmay include at least one opening though which at least one energy beamfrom the energy source can be directed to the portion of the filamentlayer. The system for printing at least a portion of the 3D object canfurther comprise an additional energy source that provides energy to aremainder of the filament material layer that did not fuse tosubsequently form at least a portion of the 3D object.

During printing of the three-dimensional object, certain parameters maybe critical to printing high quality parts. One or more sensors can beused to measure one or more temperature(s) along at least one filamentmaterial. Such sensors can control intensities, positions, and/or anglesof at least the first energy beam. The one or more sensors may be anoptical pyrometer. The controller may direct the optical pyrometers tobe aimed at the nip points and one or more points before and/or afterthe compaction unit to detect the temperature of the at least onefilament materials as they are deposited. The temperature may vary fromregion to region of the filament material layer. Factors that affecttemperature variance can include variable heater irradiance, variationsin absorptivity of the composition, substrate temperature, filamentmaterial temperature, unfused filament material temperature, and the useof modifiers and additives. Accordingly, the controller may beprogrammed so that the image and temperature measurement inputs basedupon layer temperature patterns captured by the one or more sensors maybe used. The real time temperature inputs and the sintering model may befactors determining an energy requirement pattern for any one or moresubsequent layers.

Additionally, the system may comprise a real time simulation program, asample as shown in FIG. 4, to provide feedback control of a givenlocation, direction, or angle of at least the first energy beam normalto the substrate and/or along the substrate among one or more locations,directions, or angles. The sample real time simulation of the opticalbeam path illustrates that choosing the appropriate wedge angle andenergy beam orientation may result in the elliptical beam profile inFIG. 4. The real time simulation program may be a feedback controlsystem. The feedback control system may be a Zemax simulation of thebeam propagation.

Other parameters critical to printing high quality parts can includesubstrate temperature, melt zone temperature, as-built geometry, surfaceroughness and texture and density. Other critical visible or non-visiblemetrics include characterization of chemistry, bonding or adhesionstrength. Measuring one or more structural or internal properties of thepart can comprise one or more methods selected from the group consistingof scattered and reflected or absorbed radiation, x-ray imaging, soundwaves, scatterometry techniques, ultrasonic techniques, X-rayPhotoelectron Spectroscopy (XPS), Four Transform Infrared Spectroscopy(FTIR), Raman Spectroscopy, Laser-Microprobe Mass Spectrometry (LMMS),and any combination thereof. Specific metrology beneficial to the endgoals of characterizing the critical process parameters can be used.This in-situ metrology coupled with fast processing of data can enableopen or closed loop control of the manufacturing process. Sensorsappropriate to the key parameters of interest can be selected andutilized during the part printing process. The sensors may also comprisea camera for detecting light in the infrared or visible portion of theelectromagnetic spectrum. Sensors such as IR cameras may be used tomeasure temperature fields. An image processing algorithm may be used toevaluate data generated by one or more sensors, to extract one or morestructural or internal properties of the part. Visual (e.g., highmagnification) microscopy from digital camera(s) can be used with propersoftware processing to detect voids, defects, and surface roughness. Inorder to utilize this technique, potentially large quantities of datamay need to be interrogated using image processing algorithms in orderto extract features of interest. Scatterometry techniques may be adaptedto provide roughness or other data.

Ultrasonic techniques can be used to measure solid density and fiber andparticle density which in turn may be useful in characterizing bondstrength and fiber dispersion. The characterization can affect materialstrength. Ultrasonic techniques can also be used to measure thickness offeatures. Chemical bonding characterization, which may be useful forunderstanding fiber and/or matrix adhesion and layer-to-layer bonding,can be performed by multiple techniques such as X-ray PhotoelectronSpectroscopy (XPS), Four Transform Infrared Spectroscopy (FTIR) andRaman Spectroscopy and Laser-Microprobe Mass Spectrometry (LMMS). One ormore of these techniques may be utilized as part of the in-situmetrology for 3D printing. Ex-situ techniques may also be utilized inorder to help provide appropriate calibration data for the in-situtechniques.

Sensors may be positioned on the robot end-effector of thethree-dimensional printer in order to provide a sensor moving along withthe deposited material. A robot end-effector may be a device positionedat the end of a robotic arm. The robot end-effector may be programmed tointeract with its surrounding environment. Sensors may be also locatedat other various positions. The positions can be on-board the robot, onthe effector, or deployed in the environment. Sensors may be incommunication with the system. The system can further comprise one ormore processors, a communication unit, memory, power supply, andstorage. The communications unit can comprise an input and an output.The communication unit can be wired or wireless. The sensor measurementsmay or may not be stored in a database, and may or may not be used infuture simulation and optimization operations. In-situ measurements mayalso be made using alternative methods with sensors in a cell but notdirectly attached to the robot end-effector.

Computer Control Systems

The present disclosure provides computer control systems that areprogrammed to implement methods of the disclosure. FIG. 5 shows acomputer system 501 that is programmed or otherwise configured toimplement 3D printing methods and systems of the present disclosure. Thecomputer system 501 can regulate various aspects of methods the presentdisclosure, such as, for example, partitioning a computer model of apart and generating a mesh array from the computer model.

The computer system 501 includes a central processing unit (CPU, also“processor” and “computer processor” herein) 505, which can be a singlecore or multi core processor, or a plurality of processors for parallelprocessing. The computer system 501 also includes memory or memorylocation 510 (e.g., random-access memory, read-only memory, flashmemory), electronic storage unit 515 (e.g., hard disk), communicationinterface 520 (e.g., network adapter) for communicating with one or moreother systems, and peripheral devices 525, such as cache, other memory,data storage and/or electronic display adapters. The memory 510, storageunit 515, interface 520 and peripheral devices 525 are in communicationwith the CPU 505 through a communication bus (solid lines), such as amotherboard. The storage unit 515 can be a data storage unit (or datarepository) for storing data. The computer system 501 can be operativelycoupled to a computer network (“network”) 530 with the aid of thecommunication interface 520. The network 530 can be the Internet, aninternet and/or extranet, or an intranet and/or extranet that is incommunication with the Internet. The network 530 in some cases is atelecommunication and/or data network. The network 530 can include oneor more computer servers, which can enable distributed computing, suchas cloud computing. The network 530, in some cases with the aid of thecomputer system 501, can implement a peer-to-peer network, which mayenable devices coupled to the computer system 501 to behave as a clientor a server.

The CPU 505 can execute a sequence of machine-readable instructions,which can be embodied in a program or software. The instructions may bestored in a memory location, such as the memory 510. The instructionscan be directed to the CPU 505, which can subsequently program orotherwise configure the CPU 505 to implement methods of the presentdisclosure. Examples of operations performed by the CPU 505 can includefetch, decode, execute, and writeback.

The CPU 505 can be part of a circuit, such as an integrated circuit. Oneor more other components of the system 501 can be included in thecircuit. In some cases, the circuit is an application specificintegrated circuit (ASIC).

The storage unit 515 can store files, such as drivers, libraries andsaved programs. The storage unit 515 can store user data, e.g., userpreferences and user programs. The computer system 501 in some cases caninclude one or more additional data storage units that are external tothe computer system 501, such as located on a remote server that is incommunication with the computer system 501 through an intranet or theInternet.

The computer system 501 can communicate with one or more remote computersystems through the network 530. For instance, the computer system 501can communicate with a remote computer system of a user (e.g., customeror operator of a 3D printing system). Examples of remote computersystems include personal computers (e.g., portable PC), slate or tabletPC's (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, Smart phones(e.g., Apple® iPhone, Android-enabled device, Blackberry®), or personaldigital assistants. The user can access the computer system 501 via thenetwork 530.

Methods as described herein can be implemented by way of machine (e.g.,computer processor) executable code stored on an electronic storagelocation of the computer system 501, such as, for example, on the memory510 or electronic storage unit 515. The machine executable or machinereadable code can be provided in the form of software. During use, thecode can be executed by the processor 505. In some cases, the code canbe retrieved from the storage unit 515 and stored on the memory 510 forready access by the processor 505. In some situations, the electronicstorage unit 515 can be precluded, and machine-executable instructionsare stored on memory 510.

The code can be pre-compiled and configured for use with a machinehaving a processor adapted to execute the code, or can be compiledduring runtime. The code can be supplied in a programming language thatcan be selected to enable the code to execute in a pre-compiled oras-compiled fashion.

Aspects of the systems and methods provided herein, such as the computersystem 1801, can be embodied in programming. Various aspects of thetechnology may be thought of as “products” or “articles of manufacture”typically in the form of machine (or processor) executable code and/orassociated data that is carried on or embodied in a type of machinereadable medium. Machine-executable code can be stored on an electronicstorage unit, such as memory (e.g., read-only memory, random-accessmemory, flash memory) or a hard disk. “Storage” type media can includeany or all of the tangible memory of the computers, processors or thelike, or associated modules thereof, such as various semiconductormemories, tape drives, disk drives and the like, which may providenon-transitory storage at any time for the software programming. All orportions of the software may at times be communicated through theInternet or various other telecommunication networks. Suchcommunications, for example, may enable loading of the software from onecomputer or processor into another, for example, from a managementserver or host computer into the computer platform of an applicationserver. Thus, another type of media that may bear the software elementsincludes optical, electrical and electromagnetic waves, such as usedacross physical interfaces between local devices, through wired andoptical landline networks and over various air-links. The physicalelements that carry such waves, such as wired or wireless links, opticallinks or the like, also may be considered as media bearing the software.As used herein, unless restricted to non-transitory, tangible “storage”media, terms such as computer or machine “readable medium” refer to anymedium that participates in providing instructions to a processor forexecution.

Hence, a machine readable medium, such as computer-executable code, maytake many forms, including but not limited to, a tangible storagemedium, a carrier wave medium or physical transmission medium.Non-volatile storage media include, for example, optical or magneticdisks, such as any of the storage devices in any computer(s) or thelike, such as may be used to implement the databases, etc. shown in thedrawings. Volatile storage media include dynamic memory, such as mainmemory of such a computer platform. Tangible transmission media includecoaxial cables; copper wire and fiber optics, including the wires thatcomprise a bus within a computer system. Carrier-wave transmission mediamay take the form of electric or electromagnetic signals, or acoustic orlight waves such as those generated during radio frequency (RF) andinfrared (IR) data communications. Common forms of computer-readablemedia therefore include for example: a floppy disk, a flexible disk,hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD orDVD-ROM, any other optical medium, punch cards paper tape, any otherphysical storage medium with patterns of holes, a RAM, a ROM, a PROM andEPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wavetransporting data or instructions, cables or links transporting such acarrier wave, or any other medium from which a computer may readprogramming code and/or data. Many of these forms of computer readablemedia may be involved in carrying one or more sequences of one or moreinstructions to a processor for execution.

The computer system 501 can include or be in communication with anelectronic display 535 that comprises a user interface (UI) 540 forproviding, for example, a print head tool path to a user. Examples ofUI's include, without limitation, a graphical user interface (GUI) andweb-based user interface.

Methods and systems of the present disclosure can be implemented by wayof one or more algorithms. An algorithm can be implemented by way ofsoftware upon execution by the central processing unit 505. Thealgorithm can, for example, partition a computer model of a part andgenerate a mesh array from the computer model.

The computer system 501 can include a 3D printing system. The 3Dprinting system may include one or more 3D printers. A 3D printer maybe, for example, a fused filament fabrication (FFF) printer.Alternatively or in addition to, the computer system 501 may be inremote communication with the 3D printing system, such as through thenetwork 530.

EXAMPLES Example 1

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed without extrusion by firstreceiving, in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedthrough a nozzle towards a substrate that is configured to support the3D object. A first layer may be deposited corresponding to a portion ofthe 3D object adjacent to the substrate. The first layer in the X and Ydirection may be deposited in accordance with the model of the 3Dobject. Additional layers may be deposited onto the first layer in the Zdirection. A final layer of at filament material may be deposited. Thesystem may comprise a heater cartridge with thermal control from PIDcontrollers connected to thermocouples. During deposition, the heatercartridges may control the temperature for the system in accordance withthe parameters for building the model of the 3D object. Thethermocouples may provide feedback to the PID controller and maymaintain temperature set points throughout the build process. A laserbeam may then be used to selectively melt several portions of the firstand last deposited layer, thereby increasing adherence and fusionbetween adjacent layers. A part of the modulated laser beam may befocused by the focusing system, angled by a pair of optical wedges, andirradiated along the filament material for three-dimensional printing.The 3D object may be allowed to cool prior to removing the object fromthe substrate. The 3D object may be packaged and then delivered to thecustomer.

Example 2

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed without extrusion by firstreceiving, in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedthrough a nozzle towards a substrate that is configured to support the3D object. A first layer may be deposited corresponding to a portion ofthe 3D object adjacent to the substrate. The first layer in the X and Ydirection may be deposited in accordance with the model of the 3Dobject. Additional layers may be deposited onto the first layer in the Zdirection. A final layer of at filament material may be deposited. Thesystem may comprise a heater cartridge with thermal control from PIDcontrollers connected to thermocouples. During deposition, the heatercartridges may control the temperature for the system in accordance withthe parameters for building the model of the 3D object. Thethermocouples may provide feedback to the PID controller and maymaintain temperature set points throughout the build process. A hotfluid may then be used to selectively melt several portions of the firstand last deposited layer, thereby increasing adherence and fusionbetween adjacent layers. The 3D object may be allowed to cool prior toremoving the object from the substrate. The 3D object may be packagedand then delivered to the customer.

Example 3

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed without extrusion by firstreceiving in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedthrough a nozzle towards a substrate that is configured to support the3D object. A first layer can be deposited corresponding to a portion ofthe 3D object adjacent to the substrate, in accordance with the model ofthe 3D object. A laser beam may then be used to selectively melt severalportions of the first layer. Specifically, the laser beam may bedirected to the section of the build object where the subsequent segmentmay be deposited. A part of the modulated laser beam may be focused bythe focusing system, angled by a pair of optical wedges, and irradiatedalong the filament material for three-dimensional printing. The meltpool can span the entire thickness of the printed segment, therebyincreasing the adhesion across segments built in the same layer. Next, asecond layer of at least a portion of the 3D object may be deposited.This process may be repeated until the 3D object is built. The systemmay comprise a heater cartridge with thermal control from PIDcontrollers connected to thermocouples. During deposition, the heatercartridges may control the temperature for the system in accordance withthe parameters for building the model of the 3D object. Thethermocouples may provide feedback to the PID controller and maymaintain temperature set points throughout the build process. Uponcompletion of the build, the 3D object may be allowed to cool prior toremoving the object from the substrate. The 3D object may be packagedand then delivered to the customer.

Example 4

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed without extrusion by firstreceiving in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedthrough a nozzle towards a substrate that is configured to support the3D object. A first layer can be deposited corresponding to a portion ofthe 3D object adjacent to the substrate, in accordance with the model ofthe 3D object. A convective hot fluid (e.g., hot air) may then be usedto selectively melt several portions of the first layer. Specifically,the convective hot fluid may be directed to the section of the buildobject where the subsequent segment may be deposited. The melt pool canspan the entire thickness of the printed segment, thereby increasing theadhesion across segments built in the same layer. Next, a second layerof at least a portion of the 3D object may be deposited. This processmay be repeated until the 3D object is built. The system may comprise aheater cartridge with thermal control from PID controllers connected tothermocouples. During deposition, the heater cartridges may control thetemperature for the system in accordance with the parameters forbuilding the model of the 3D object. The thermocouples may providefeedback to the PID controller and may maintain temperature set pointsthroughout the build process. Upon completion of the build, the 3Dobject may be allowed to cool prior to removing the object from thesubstrate. The 3D object may be packaged and then delivered to thecustomer.

Example 5

In an example, prior to printing the 3D object, a request for productionof a requested 3D object may be received from a user (e.g., customer).At least a portion of a 3D object may be printed without extrusion byfirst receiving in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool through anextender mechanism toward a channel of the print head. The extendermechanism can include a motor for dispensing at least one filamentmaterial. This composite filament material may be directed from thespool to a channel of the print head through a nozzle towards thesubstrate. Additionally, the substrate can include a drive mechanism formoving the substrate as each layer is deposited onto the substrate.

From the nozzle, the composite filament material may be directed to atleast one freely suspended roller, thereby depositing a first layercorresponding to a portion of the 3D object on the substrate. Thecomposite filament may be fed into a nozzle at an angle such that it isfed under at least one freely suspended roller at a nip point as thefreely suspended roller presses the filament material exiting from thenozzle. The freely suspended roller may be designed to control the bendradii of the composite filament material.

Next, the second layer of the 3D object may be deposited. One or moreadditional layers can be deposited adjacent to the first layer prior todepositing the second layer. At least a first energy beam from at leastone energy source may be used to selectively melt at least a portion ofthe first layer and/or the second layer, thereby forming at least aportion of the 3D object. The energy beam may be a laser beam. Theenergy source may be in optical communication with one or more beamsplitters, which one or more beam splitters can split an energy beamfrom at least one light source into one or more beamlets that yields atleast the first energy beam.

The energy source may be a laser head that is mounted on a robot orsimilar mechanism that swivels around the vertical axis enablingdeposition in any direction in the plane of deposition. Duringdeposition, optical pyrometers may be aimed at the substrate to detectthe temperature of the composite filament materials as they aredeposited. A real time simulation program (FIG. 4) may also be used toprovide feedback control of a given location, direction, or angle of thelaser beam normal to the substrate and/or along the substrate among oneor more locations, directions, or angles. The sample real timesimulation of the optical beam path illustrates that choosing theappropriate wedge angle and energy beam orientation may result in theelliptical beam profile in FIG. 4. The real time simulation program maybe a feedback control system. The feedback control system may be a Zemaxsimulation of the beam propagation. Upon completion of the build, the 3Dobject may be allowed to cool prior to removing the object from thesubstrate. The 3D object may be packaged and then delivered to thecustomer.

Example 6

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed with extrusion by firstreceiving, in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedand extruded through a nozzle towards a substrate that is configured tosupport the 3D object. A first layer may be deposited corresponding to aportion of the 3D object adjacent to the substrate. The first layer inthe X and Y direction may be deposited in accordance with the model ofthe 3D object. Additional layers may be deposited onto the first layerin the Z direction. A final layer of at filament material may bedeposited. The system may comprise a heater cartridge with thermalcontrol from PID controllers connected to thermocouples. Duringdeposition, the heater cartridges may control the temperature for thesystem in accordance with the parameters for building the model of the3D object. The thermocouples may provide feedback to the PID controllerand may maintain temperature set points throughout the build process. Alaser beam may then be used to selectively melt several portions of thefirst and last deposited layer, thereby increasing adherence and fusionbetween adjacent layers. A part of the modulated laser beam may befocused by the focusing system, angled by a pair of optical wedges, andirradiated along the filament material for three-dimensional printing.The 3D object may be allowed to cool prior to removing the object fromthe substrate. The 3D object may be packaged and then delivered to thecustomer.

Example 7

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed with extrusion by firstreceiving, in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedand extruded through a nozzle towards a substrate that is configured tosupport the 3D object. A first layer may be deposited corresponding to aportion of the 3D object adjacent to the substrate. The first layer inthe X and Y direction may be deposited in accordance with the model ofthe 3D object. Additional layers may be deposited onto the first layerin the Z direction. A final layer of at filament material may bedeposited. The system may comprise a heater cartridge with thermalcontrol from PID controllers connected to thermocouples. Duringdeposition, the heater cartridges may control the temperature for thesystem in accordance with the parameters for building the model of the3D object. The thermocouples may provide feedback to the PID controllerand may maintain temperature set points throughout the build process. Ahot fluid may then be used to selectively melt several portions of thefirst and last deposited layer, thereby increasing adherence and fusionbetween adjacent layers. The 3D object may be allowed to cool prior toremoving the object from the substrate. The 3D object may be packagedand then delivered to the customer.

Example 8

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed with extrusion by firstreceiving in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedand extruded through a nozzle towards a substrate that is configured tosupport the 3D object. A first layer can be deposited corresponding to aportion of the 3D object adjacent to the substrate, in accordance withthe model of the 3D object. A laser beam may then be used to selectivelymelt several portions of the first layer. Specifically, the laser beammay be directed to the section of the build object where the subsequentsegment may be deposited. A part of the modulated laser beam may befocused by the focusing system, angled by a pair of optical wedges, andirradiated along the filament material for three-dimensional printing.The melt pool can span the entire thickness of the printed segment,thereby increasing the adhesion across segments built in the same layer.Next, a second layer of at least a portion of the 3D object may bedeposited. This process may be repeated until the 3D object is built.The system may comprise a heater cartridge with thermal control from PIDcontrollers connected to thermocouples. During deposition, the heatercartridges may control the temperature for the system in accordance withthe parameters for building the model of the 3D object. Thethermocouples may provide feedback to the PID controller and maymaintain temperature set points throughout the build process. Uponcompletion of the build, the 3D object may be allowed to cool prior toremoving the object from the substrate. The 3D object may be packagedand then delivered to the customer.

Example 9

In an example, prior to printing the 3D object, a request for productionof a requested 3D object is received from a user (e.g., customer). Atleast a portion of a 3D object may be printed with extrusion by firstreceiving in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool toward achannel of the print head. The filament material may then be directedand extruded through a nozzle towards a substrate that is configured tosupport the 3D object. A first layer can be deposited corresponding to aportion of the 3D object adjacent to the substrate, in accordance withthe model of the 3D object. A convective hot fluid (e.g., hot air) maythen be used to selectively melt several portions of the first layer.Specifically, the convective hot fluid may be directed to the section ofthe build object where the subsequent segment may be deposited. The meltpool can span the entire thickness of the printed segment, therebyincreasing the adhesion across segments built in the same layer. Next, asecond layer of at least a portion of the 3D object may be deposited.This process may be repeated until the 3D object is built. The systemmay comprise a heater cartridge with thermal control from PIDcontrollers connected to thermocouples. During deposition, the heatercartridges may control the temperature for the system in accordance withthe parameters for building the model of the 3D object. Thethermocouples may provide feedback to the PID controller and maymaintain temperature set points throughout the build process. Uponcompletion of the build, the 3D object may be allowed to cool prior toremoving the object from the substrate. The 3D object may be packagedand then delivered to the customer.

Example 10

In an example, prior to printing the 3D object, a request for productionof a requested 3D object may be received from a user (e.g., customer).At least a portion of a 3D object may be printed with extrusion by firstreceiving in computer memory, a model of the 3D object. Next, acomposite filament material may be directed from a spool through anextender mechanism toward a channel of the print head. The compositefilament material may be extruded from the nozzle of the print heat. Theextender mechanism can include a motor for dispensing at least onefilament material. This composite filament material may be directed fromthe spool to a channel of the print head through a nozzle towards thesubstrate. Additionally, the substrate can include a drive mechanism formoving the substrate as each layer is deposited onto the substrate.

From the nozzle, the composite filament material may be directed to atleast one freely suspended roller, thereby depositing a first layercorresponding to a portion of the 3D object on the substrate. Thecomposite filament may be fed into a nozzle at an angle such that it isfed under at least one freely suspended roller at a nip point as thefreely suspended roller presses the filament material exiting from thenozzle. The freely suspended roller may be designed to control the bendradii of the composite filament material.

Next, the second layer of the 3D object may be deposited. One or moreadditional layers can be deposited adjacent to the first layer prior todepositing the second layer. At least a first energy beam from at leastone energy source may be used to selectively melt at least a portion ofthe first layer and/or the second layer, thereby forming at least aportion of the 3D object. The energy beam may be a laser beam. Theenergy source may be in optical communication with one or more beamsplitters, which one or more beam splitters can split an energy beamfrom at least one light source into one or more beamlets that yields atleast the first energy beam.

The energy source may be a laser head that is mounted on a robot orsimilar mechanism that swivels around the vertical axis enablingdeposition in any direction in the plane of deposition. Duringdeposition, optical pyrometers may be aimed at the substrate to detectthe temperature of the composite filament materials as they aredeposited. A real time simulation program (FIG. 4) may also be used toprovide feedback control of a given location, direction, or angle of thelaser beam normal to the substrate and/or along the substrate among oneor more locations, directions, or angles. The sample real timesimulation of the optical beam path illustrates that choosing theappropriate wedge angle and energy beam orientation may result in theelliptical beam profile in FIG. 4. The real time simulation program maybe a feedback control system. The feedback control system may be a Zemaxsimulation of the beam propagation. Upon completion of the build, the 3Dobject may be allowed to cool prior to removing the object from thesubstrate. The 3D object may be packaged and then delivered to thecustomer.

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. It is not intendedthat the invention be limited by the specific examples provided withinthe specification. While the invention has been described with referenceto the aforementioned specification, the descriptions and illustrationsof the embodiments herein are not meant to be construed in a limitingsense. Numerous variations, changes, and substitutions will now occur tothose skilled in the art without departing from the invention.Furthermore, it shall be understood that all aspects of the inventionare not limited to the specific depictions, configurations or relativeproportions set forth herein which depend upon a variety of conditionsand variables. It should be understood that various alternatives to theembodiments of the invention described herein may be employed inpracticing the invention. It is therefore contemplated that theinvention shall also cover any such alternatives, modifications,variations or equivalents. It is intended that the following claimsdefine the scope of the invention and that methods and structures withinthe scope of these claims and their equivalents be covered thereby.

What is claimed is:
 1. A system for printing at least a portion of athree-dimensional (3D) object, comprising: a source of at least onefilament material that is configured to supply at least one filamentmaterial for generating said at least said portion of 3D object; asubstrate for supporting said at least said portion of said 3D objectduring printing; a printing unit that is configured to direct said atleast one filament material from said source of said at least onefilament material towards said substrate; at least one energy sourceconfigured to deliver energy to a first layer and/or a second layer ofsaid at least said portion of said 3D object; and a controlleroperatively coupled to said printing unit and said at least one energysource, wherein said controller is programmed to (i) receive, incomputer memory, a model of said 3D object, (ii) subsequent to receivingsaid model of said 3D object, direct said printing unit to direct saidat least one filament material from said source of said at least onefilament material towards said substrate, thereby depositing a firstlayer corresponding to said portion of said 3D object adjacent to saidsubstrate, which first layer is deposited in accordance with said modelof said 3D object, (iii) direct said printing unit to deposit a secondlayer corresponding to at least a portion of said 3D object, whichsecond layer is deposited in accordance with said model of said 3Dobject, and (iv) use energy from at least one energy source toselectively melt at least a portion of said first layer and/or saidsecond layer, thereby printing said at least said portion of said 3Dobject.
 2. The system of claim 1, wherein said controller is furtherprogrammed to use said energy from said at least one energy source toselectively melt at least a portion of said first layer and said secondlayer.
 3. The system of claim 1, wherein said controller is furtherprogrammed to deposit one or more additional layers adjacent to saidfirst layer prior to depositing said second layer.
 4. The system ofclaim 1, wherein said printing unit comprises an opening that isconfigured to (i) receive said at least one filament material, and (ii)direct said at least one filament material towards said substrate. 5.The system of claim 1, further comprising a compaction unit to compactsaid at least one filament material along said substrate, wherein saidcompaction unit comprises a rigid body, one or more idler rollers, atleast one freely suspended roller, a coolant unit, or any combinationthereof.
 6. The system of claim 1, further comprising one or moresensors to measure one or more temperature(s) along said at least onefilament material during said printing.
 7. The system of claim 1,wherein said substrate comprises a drive unit for moving said substrate.8. The system of claim 1, wherein said at least one filament material isa continuous fiber composite.
 9. The system of claim 8, wherein saidcontinuous fiber composite comprises a polymeric material and areinforcing material.
 10. The system of claim 8, wherein said continuousfiber composite includes one or more materials selected from the groupconsisting of glass, carbon, aramid, cotton, silicon carbide, polymer,wool, and metal.
 11. The system of claim 1, wherein said at least onefilament material has a diameter from about 0.1 millimeters to 5millimeters.
 12. The system of claim 1, wherein said at least one energysource is a laser and/or source of a hot fluid.
 13. The system of claim1, further comprising an optical unit in which at least one energysource is in optical communication with one or more beam splitters,which one or more beam splitters splits an energy beam from said atleast one energy source into one or more beamlets that yield at leastone energy beam.
 14. The system of claim 13, wherein said at least oneenergy source is configured to deliver said at least one energy beamsuch that it is incident on said at least one filament material and (i)said substrate or (ii) said first layer and/or said second layer. 15.The system of claim 13, wherein said optical unit comprises one or moreelements selected from the group consisting of a beam splitter, focusinglens, and an optical wedge.
 16. The system of claim 13, wherein saidoptical unit comprises a first optical wedge and a second optical wedge.17. The system of claim 1, wherein said controller is further programmedto direct a real time simulation program for providing feedback duringprinting of said 3D object.
 18. The system of claim 1, wherein said atleast one energy source comprises a convective fluid source, and whereinsaid controller is programmed to direct flow of a convective fluid fromsaid convective fluid source to said first layer and/or said secondlayer to provide said energy to selectively melt said at least saidportion of said first layer and/or said second layer.
 19. The system ofclaim 18, wherein said convective fluid is directed through saidprinting unit.
 20. The system of claim 1, further comprising a feedbackcontrol system that is configured to (i) measure one or more propertiesof said first layer and/or said second layer during said printing, and(ii) adjust one or more process parameters associated with said energyor said at least one energy source based on said one or more propertiesmeasured in (i).